U.S. patent application number 14/490989 was filed with the patent office on 2015-01-08 for volume dimensioning system calibration systems and methods.
The applicant listed for this patent is Intermec IP Corporation. Invention is credited to H. Sprague Ackley, Franck Laffargue, Serge Thuries.
Application Number | 20150009338 14/490989 |
Document ID | / |
Family ID | 50099789 |
Filed Date | 2015-01-08 |
United States Patent
Application |
20150009338 |
Kind Code |
A1 |
Laffargue; Franck ; et
al. |
January 8, 2015 |
VOLUME DIMENSIONING SYSTEM CALIBRATION SYSTEMS AND METHODS
Abstract
Various corporate, industry, and regulatory guidelines, best
practices and standards are used in establishing acceptable levels
of accuracy for volume dimensioning systems used in commerce. A
volume dimensioning system can determine at least one distortion
value that is indicative of an amount of distortion present in the
system and responsive to the amount of distortion, autonomously
after or adjust the units of accuracy of information reported by
the system. Such alteration or adjustment of units of accuracy may
be performed based on an assessment of the distortion relative to a
number of distortion thresholds. Responsive to the assessment, the
volume dimensioning system can adjust a unit of accuracy in a
representation of volume dimensioning related information.
Inventors: |
Laffargue; Franck;
(Toulouse, FR) ; Thuries; Serge; (Saint Jean,
FR) ; Ackley; H. Sprague; (Seattle, WA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Intermec IP Corporation |
Fort Mill |
SC |
US |
|
|
Family ID: |
50099789 |
Appl. No.: |
14/490989 |
Filed: |
September 19, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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|
13786131 |
Mar 5, 2013 |
|
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14490989 |
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61691093 |
Aug 20, 2012 |
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Current U.S.
Class: |
348/175 |
Current CPC
Class: |
G01F 17/00 20130101;
H04N 17/002 20130101; G01F 25/0084 20130101 |
Class at
Publication: |
348/175 |
International
Class: |
H04N 17/00 20060101
H04N017/00 |
Claims
1. A method of calibrating position and orientation parameters of
an imaging system in an automated data reading system, the method
comprising: obtaining, from the imaging system, image data
representing an imaged portion of a planar calibration target that
is superimposed on a surface of the automated data reading system,
the imaged portion of the planar calibration target including
spaced-apart optical codes disposed at predetermined positions on a
surface of the automated data reading system to define known
locations of calibration-control points on the surface; identifying
the optical codes from the image data to obtain observed locations
of the calibration-control points represented by the image data;
and calibrating position and orientation parameters of the imaging
system based on differences between the known and observed
locations.
Description
BACKGROUND
[0001] 1. Field
[0002] This disclosure generally relates to volume dimensioning
systems, and particularly to systems and methods useful in the
promoting compliance with governmental or industry standard
calibration guidelines.
[0003] 2. Description of the Related Art
[0004] Volume dimensioning systems are useful for providing
dimensional and/or volumetric information related to
three-dimensional objects. The objects may, for example take the
form of parcels or packages intended for transit via a carrier
(e.g., courier) or other items intended for transit. Dimensional
and/or volumetric information is useful for example, in providing
users with accurate shipping rates based on the actual size and/or
volume of the object being shipped. Dimensional and/or volumetric
information may be used by the carrier in selecting and scheduling
appropriately sized vehicles and/or delivery routes. The ready
availability of dimensional and/or volumetric information for all
objects within a carrier's network assists the carrier in ensuring
optimal use of available space in the many different vehicles and
containers used in local, interstate, and international
shipping.
[0005] Such may be of particular significant in today's economy
where many businesses rely on "just in time" manufacturing.
Typically, every supplier in the supply chain must be able to ship
necessary components or resources on demand or with very little
lead time. Thus, efficient handling of cargo is required. It does a
supplier no good to have the desired goods on hand, if the supplier
cannot readily ship the desired goods.
[0006] Automating volume dimensioning can speed parcel intake,
improve the overall level of billing accuracy, and increase the
efficiency of cargo handling. Unfortunately, parcels are not
confined to a standard size or shape, and may, in fact, have
virtually any size or shape. Additionally, parcels may also have
specialized shipping and/or handling instructions (e.g., fragile,
this side up) that must be followed during shipping or handling to
protect the objects during shipping.
[0007] Volume dimensioning devices are used throughout the package
delivery and carriage industry to provide a rapid way of measuring
the overall dimensions of an object and, in some instances, to
provide shipping rates for the object based on one or more classes
of service. Historically, shipping rates were principally a
function of an object's weight--heavier objects were assigned
higher shipping costs than lighter objects. However, such a costing
system failed to appreciate that volume the volume occupied by an
object also impacted shipping costs since vehicles were not just
limited in gross vehicle weight, but internal volume as well. As a
consequence shippers began establishing shipping rates using both
volume and weight as factors considered in determining the ultimate
shipping rate charged to a customer.
[0008] The concept of volume dimensioning factors the shipping
volume of an object into the overall shipping cost of an object.
Thus, objects having a relatively light weight but a relatively
large physical volume may have a shipping cost that exceeds the
shipping cost of a physically smaller, but heavier, object. The use
of volume in determining shipping costs increased the labor
associated with package intake, since objects could no longer
simply be weighed and a cost assigned. Instead, to accurately
obtain a volume dimension, multiple dimensional measurements were
taken and used to determine the volume of the object. Once the
volume is determined, a shipping cost is assigned based on the
measured volume and/or weight of the object. Thus, the shipping
cost charged a customer is a function of the weight of an object,
the volume occupied by the object, or both the weight of and the
volume occupied by the object. Automated volume dimensioning
systems have replaced the laborious and error prone derivation of
an object's volume by manually obtaining multiple linear dimensions
(e.g., the length, width, height, girth, etc.) of an object. The
accuracy of a quoted shipping rate is thus dependent upon the
accuracy with which an object can be dimensioned using a volume
dimensioning system.
[0009] There exists a need for new dimensioning systems that may
accurately perform volume dimensioning of objects including parcels
and packages as well as other objects.
BRIEF SUMMARY
[0010] The Applicants have developed systems and methods useful for
adjusting the reported or displayed dimensional measurement
accuracy and consequently the reported or displayed shipping or
cartage rate obtained using dimensional or volumetric data supplied
by the volume dimensioning system. The systems and methods
described herein take into consideration the level of distortion
(e.g., dimensional distortion, optical distortion, etc.) present in
the image data provided by such automated volume dimensioning
systems. In some instances, the system adjusts a dimensional
accuracy of a representation of volume dimensioning information
(e.g., dimensions, cost based on the measured distortion present in
the volume dimensioning system). Such may ensure that the
dimensional and shipping cost data generated by the system is
determined using the finest units of accuracy achievable given the
current system operational parameters to reliably provide the most
accurate shipping or cartage costs. Such systems and methods can be
used to promote or facilitate volume dimensioning system compliance
with corporate, industry, or regulatory standards, best practices,
or guidelines, for example National Institute of Standards (NIST)
Handbook 44-2012 Chapter 5.58--"Multiple Dimension Measuring
Devices".
[0011] The systems and methods disclosed herein also facilitate the
ongoing, operationally transparent, calibration of volume
dimensioning systems. Such ongoing calibrations provide system
users and consumers with a degree of confidence in the dimensional
and shipping cost data provided by the volume dimensioning system
and also provide an early indication that the system calibration
can no longer be brought into compliance with corporate, industry,
or regulatory standards, best practices, or guidelines.
[0012] A volume dimensioning system may be summarized as including
at least one image sensor that provides image data representative
of a number of images of a field of view of the at least one image
sensor; and a control subsystem communicatively coupled to the at
least one image sensor to receive the image data therefrom, the
control subsystem including at least one nontransitory storage
medium and at least one processor, the at least one nontransitory
storage medium which stores at least one of information or
processor executable instructions; and the at least one processor
which: determines at least one distortion value indicative of an
amount of distortion in the images based at least in part on at
least a portion of a calibration pattern which appears in the field
of view of the at least one image sensor in at least a portion of
some of the images, the calibration pattern having a set of defined
characteristics; assesses the at least one distortion value
relative to a number of distortion threshold values; and adjusts a
unit of accuracy in a representation of volume dimensioning related
information based at least in part on the assessment of the at
least one distortion value relative to the distortion threshold
values.
[0013] The at least one processor may determine the at least one
distortion value as at least one set of optical distortion values
and at least one set of dimensional distortion values, the set of
optical distortion values representative of an optical contribution
to distortion in the image data and the set of dimensional
distortion values representative of a dimensional contribution to
distortion in the image data. The at least one processor may assess
the at least one distortion value relative to a recalibration
threshold value that represents distortion correctable via a self
recalibration by the volume dimensioning system. The at least one
processor may assess the at least one distortion value relative to
a service required threshold value that represents distortion that
can only be corrected via a servicing of the volume dimensioning
system by a service technician. The at least one processor may
adjust the unit of accuracy in the representation of volume
dimensioning related information in response to an assessment that
the at least one distortion value exceeds the recalibration
threshold value and is below the service required threshold value.
Responsive to the determination that the at least one distortion
value is less than the recalibration threshold value, the at least
one processor may recalibrate the volume dimensioning system to a
fine unit of accuracy; and wherein responsive to the determination
that the at least one distortion value exceeds the recalibration
threshold value and is below the service required threshold value,
the at least one processor may recalibrate the volume dimensioning
system to a coarse unit of accuracy. The processor may further
produce an alert in response to an assessment that the at least one
distortion value exceeds the service required threshold value. The
processor may further determine at least one of a set of calculated
optical distortion correction factors or a set of calculated
dimensional correction factors in response to an assessment that
the at least one distortion value is within the recalibration
threshold value and wherein the processor may further apply at
least one of the set of calculated optical distortion correction
factors or the set of calculated dimensional correction factors to
the image data in determining the volume dimensioning related
information. The processor may adjust a decimal place represented
to adjust the unit of accuracy in the representation of volume
dimensioning related information. The processor may adjust a
dimensional unit of measurement represented to adjust the unit of
accuracy in the representation of volume dimensioning related
information. The processor may adjust a unit of currency
represented to adjust the unit of accuracy in the representation of
volume dimensioning related information. The volume dimensioning
system may further include an illumination subsystem communicably
coupled to the control subsystem, the illumination subsystem to at
least partially illuminate the calibration pattern. The volume
dimensioning system may further include a support structure to
receive at least the at least one image sensor such that when the
at least one image sensor is received by the support structure at
least a portion of the pattern is within a field of view of the at
least one image sensor. The system may be fixed or hand held. The
at least one distortion value may be associated with at least one
of data indicative of a date or data indicative of a time and
wherein the at least one distortion value and the respective
associated data indicative of a date or data indicative of a time
may be stored in the non-transitory storage medium.
[0014] A volume dimensioning method may be summarized as including
receiving by at least one dimensioning system processor image data
representative of a number of images in a field of view of at least
one image sensor; determining by the at least one dimensioning
system processor at least one distortion value indicative of an
amount of distortion in the images based at least in part on at
least a portion of a calibration pattern which appears in the field
of view of the at least one image sensor in at least some of the
images, the calibration pattern having a set of defined
characteristics; assessing by the at least one dimensioning system
processor the at least one distortion value relative to a number of
distortion threshold values stored in a non-transitory storage
medium communicably coupled to the at least one dimensioning system
processor; and adjusting by the at least one dimensioning system
processor a unit of accuracy in a representation of volume
dimensioning related information based at least in part on the
assessment of the at least one distortion value relative to the
distortion threshold values.
[0015] Assessing by the at least one dimensioning system processor
the at least one distortion value relative to a number of
distortion threshold values may include determining the at least
one distortion value as at least one set of optical distortion
values and at least one set of dimensional distortion values;
wherein the set of optical distortion values represents an optical
contribution to distortion in the image data; and wherein the set
of dimensional distortion values represent a dimensional
contribution to distortion in the image data. Assessing by the at
least one dimensioning system processor the at least one distortion
value relative to a number of distortion threshold values may
include assessing the at least one distortion value relative to a
recalibration threshold value representing distortion correctable
via a recalibration of the volume dimensioning system. Assessing by
the at least one dimensioning system processor the at least one
distortion value relative to a number of distortion threshold
values may include assessing the at least one distortion value
relative to a service required threshold value representing
distortion not correctable via recalibration of the volume
dimensioning system. Assessing by the at least one dimensioning
system processor the at least one distortion value relative to a
number of distortion threshold values may include assessing the at
least one distortion value to fall between the recalibration
threshold value and the service required threshold value,
representing distortion correctable via a recalibration of the
volume dimensioning system. Adjusting a unit of accuracy in a
representation of volume dimensioning related information based at
least in part on the assessment of the at least one distortion
value relative to the distortion threshold values may include
recalibrating the volume dimensioning system to a fine unit of
accuracy responsive to an assessment that the at least one
distortion value relative to the recalibration threshold value
indicates a distortion correctable via recalibration; recalibrating
the volume dimensioning system to a coarse unit of accuracy
responsive to an assessment that the at least one distortion value
falls between the recalibration threshold value and the service
required threshold value; and generating an alert responsive to an
assessment that the at least one distortion value relative to the
service required threshold value indicates a distortion not
correctable via recalibration. The volume dimensioning method may
further include, responsive to the determination that the at least
one distortion value is within the recalibration threshold value,
determining by the at least one dimensioning system processor at
least one of a set of calculated optical distortion correction
factors or a set of calculated dimensional correction factors; and
applying at least one of the set of calculated optical distortion
correction factors or the set of calculated dimensional correction
factors to the image data in determining the volume dimensioning
related information.
[0016] A volume dimensioning controller may be summarized as
including at least one input communicably coupled to at least one
processor, the at least one input to receive image data
representative of a number of images of a field of view of at least
one image sensor; and at least one processor communicably coupled
to the at least one non-transitory storage medium, the at least one
processor to: determine at least one distortion value indicative of
an amount of distortion in the images based at least in part on at
least a portion of a calibration pattern which appears in the field
of view of the at least one image sensor in at least some of the
images, the calibration pattern having a set of defined
characteristics; assess the at least one distortion value relative
to a number of distortion threshold values stored in the
non-transitory storage medium; and adjust a unit of accuracy in a
representation of volume dimensioning related information based at
least in part on the assessment of the at least one distortion
value relative to the distortion threshold values.
[0017] The at least one processor may determine the at least one
distortion value as at least one set of optical distortion values
and at least one set of dimensional distortion values, the set of
optical distortion values representative of an optical contribution
to distortion in the image data and the set of dimensional
distortion values representative of a dimensional contribution to
distortion in the image data. The at least one processor may assess
the at least one distortion value relative to a recalibration
threshold value that represents distortion correctable via a self
recalibration by the volume dimensioning system. The at least one
processor may assess the at least one distortion value relative to
a service required threshold value that represents distortion that
can only be corrected via a servicing of the volume dimensioning
system by a service technician. The at least one processor may
adjust the unit of accuracy in the representation of volume
dimensioning related information in response to an assessment that
the at least one distortion value exceeds the recalibration
threshold value and is below the service required threshold value.
Responsive to the determination that the at least one distortion
value is less than the recalibration threshold value, the at least
one processor may recalibrate the volume dimensioning system to a
fine unit of accuracy; and wherein responsive to the determination
that the at least one distortion value exceeds the recalibration
threshold value and is below the service required threshold value,
the at least one processor may recalibrate the volume dimensioning
system to a coarse unit of accuracy.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0018] In the drawings, identical reference numbers identify
similar elements or acts. The sizes and relative positions of
elements in the drawings are not necessarily drawn to scale. For
example, the shapes of various elements and angles are not drawn to
scale, and some of these elements are arbitrarily enlarged and
positioned to improve drawing legibility. Further, the particular
shapes of the elements as drawn, are not intended to convey any
information regarding the actual shape of the particular elements,
and have been solely selected for ease of recognition in the
drawings.
[0019] FIG. 1 is a block diagram of an example volume dimensioning
system, according to one illustrated embodiment.
[0020] FIG. 2A is a perspective view of a volume dimensioning
system displaying one example of the effects of optical distortion,
according to one illustrative embodiment.
[0021] FIG. 2B is a perspective view of a volume dimensioning
system displaying one example of the effects of dimensional
distortion, according to one illustrative embodiment.
[0022] FIG. 3 is a perspective view of an example image sensor
received by a stand member and having a reference pattern disposed
in at least a portion of the field of view of the image sensor,
according to one illustrative embodiment.
[0023] FIG. 4A is a perspective view of an example volume
dimensioning system reporting dimensions to a first unit of
accuracy based at least in part on at least one determined
distortion value, according to one illustrative embodiment.
[0024] FIG. 4B is a perspective view of an example volume
dimensioning system reporting dimensions to a second unit of based
at least in part on at least one determined distortion value,
according to one illustrative embodiment.
[0025] FIG. 5 is a flow diagram showing a high level method of
operation of a volume dimensioning system including the
determination of at least one distortion value and one or more sets
of distortion correction factors, according to one illustrated
embodiment.
[0026] FIG. 6 is a flow diagram showing a low level method of
operation of a volume dimensioning system including an assessment
of at least one set of optical distortion values and at least one
set of dimensional distortion values, according to one illustrative
embodiment.
[0027] FIG. 7 is a flow diagram showing a high level method of
operation of a volume dimensioning system incorporating the storage
and reporting of historical distortion values or correction
factors, according to one illustrated embodiment.
DETAILED DESCRIPTION
[0028] In the following description, certain specific details are
set forth in order to provide a thorough understanding of various
disclosed embodiments. However, one skilled in the relevant art
will recognize that embodiments may be practiced without one or
more of these specific details, or with other methods, components,
materials, etc. In other instances, well-known structures
associated with volume dimensioning systems, correction of optical
and dimensional distortion in single and compound lens devices,
wired, wireless and optical communications systems, and/or
automatic data collection (ADC) readers have not been shown or
described in detail to avoid unnecessarily obscuring descriptions
of the embodiments.
[0029] Unless the context requires otherwise, throughout the
specification and claims which follow, the word "comprise" and
variations thereof, such as, "comprises" and "comprising" are to be
construed in an open, inclusive sense, that is as "including, but
not limited to."
[0030] Reference throughout this specification to "one embodiment"
or "an embodiment" means that a particular feature, structure or
characteristic described in connection with the embodiment is
included in at least one embodiment. Thus, the appearances of the
phrases "in one embodiment" or "in an embodiment" in various places
throughout this specification are not necessarily all referring to
the same embodiment. Furthermore, the particular features,
structures, or characteristics may be combined in any suitable
manner in one or more embodiments.
[0031] As used in this specification and the appended claims, the
singular forms "a," "an," and "the" include plural referents unless
the content clearly dictates otherwise. It should also be noted
that the term "or" is generally employed in its broadest sense,
that is as meaning "and/or" unless the content clearly dictates
otherwise.
[0032] The headings and Abstract of the Disclosure provided herein
are for convenience only and do not interpret the scope or meaning
of the embodiments.
[0033] FIG. 1 shows a volume dimensioning system 100, according to
one illustrated embodiment.
[0034] The volume dimensioning system 100 includes a camera
subsystem 102 and control subsystem 104. The volume dimensioning
system 100 optionally includes one or more of: a user interface
(UI) subsystem 106; a communications subsystem 108 and/or an
automatic data collection (ADC) subsystem 110.
[0035] The various subsystems 102-110 may be communicatively
coupled by one or more couplers (e.g., electrically conductive
paths, wires, optical fibers), for example via one or more buses
112 (only one shown) and/or control lines 114 (only two shown). The
buses 112, or other couplers, may include power buses or lines,
data buses, instruction buses, address buses, etc., which allow
operation of the various subsystems 102-110 and interaction or
intercommunication therebetween. The various subsystems 102-110 are
each discussed in turn, below. While various individual components
are generally easily categorizable into one or another of the
subsystems, some components may be optionally implemented in one or
two or more of the subsystems 102-110. Thus, some components may be
illustrated in FIG. 1 as part of two or more subsystems 102-110.
Alternatively, some of the components illustrated in FIG. 1 as
discrete components in two or more subsystems 102-110 may be
present as a single component within a single subsystem
102-110.
[0036] The camera subsystem 102 includes an optional illumination
subsystem 116 to provide or emit electromagnetic illumination
outward from the volume dimensioning system 100 into an environment
containing a target object (not shown in FIG. 1) and a sensor
subsystem 118 to receive illumination returned (e.g., reflected,
fluoresced) from at least the target object.
[0037] The illumination subsystem 116 includes an illumination
device 120. The illumination device 120 may take the form of an
array of individually addressable or controllable elements, and
also may have a variety of forms capable of producing
electromagnetic energy having a spectral content useful for image
collection by the sensor subsystem 118. The illumination subsystem
116 will typically include an illumination driver 122 which is
coupled to control the individually addressable or controllable
elements of the illumination device 120. Alternatively, the
illumination device 120 may be controlled directly by the control
subsystem 104 without the use of a dedicated illumination driver
122.
[0038] In particular, the illumination device 120 is controlled to
produce or emit modulated electromagnetic energy in a number of
wavelengths or ranges of wavelengths. For instance, illumination
may include electromagnetic energy of wavelengths in an optical
range or portion of the electromagnetic spectrum including
wavelengths in a human-visible range or portion (e.g.,
approximately 390 nm-750 nm) and/or wavelengths in the
near-infrared (NIR) (e.g., approximately 750 nm-1400 nm) or
infrared (e.g., approximately 750 nm-1 mm) portions and/or the
near-ultraviolet (NUV) (e.g., approximately 400 nm-300 nm) or
ultraviolet (e.g., approximately 400 nm-122 nm) portions of the
electromagnetic spectrum. The particular wavelengths are exemplary
and not meant to be limiting. Other wavelengths of electromagnetic
energy may be employed.
[0039] The sensor subsystem 118 includes an image transducer or
image sensor 124, typically a two-dimensional array of
photo-sensitive or photo-responsive elements, for instance a
two-dimensional array of photodiodes or a two-dimensional array of
charge coupled devices (CODs). The sensor subsystem 118 may
optionally include a buffer 125 communicatively coupled to the
image sensor 124 to receive or otherwise acquire image data
measured, captured or otherwise sensed or acquired by the image
sensor 124. The buffer 125 may comprise a non-transitory storage
medium capable of temporarily storing image data until the image
data is further processed by the volume dimensioning system 100. In
at least some instances, the sensor subsystem 118 can include one
or more sensors, systems, or devices for reading or scanning one or
more optical machine readable symbols or radio frequency machine
readable devices such as radio frequency identification (RFID)
tags. Some possibly suitable systems are described in U.S. patent
application Ser. No. 12/638,616, filed Dec. 15, 2009 and published
as U.S. patent application publication no. US 2010-0220894, which
is incorporated by reference herein in its entirety to the extent
the subject matter therein does not contradict or conflict with the
subject matter of the instant application.
[0040] The sensor subsystem may further include one or more
distance determination sensors (not shown in FIG. 1) useful in
measuring or otherwise determining the distance between the volume
dimensioning system 100 and one or more objects within the field of
view of the image sensor 124. Such distance detection sensors can
include one or more time-of-flight sensors, sonar sensors, or
similar. In at least some instances the image sensor 124 may
advantageously include one or more distance determination features,
for example parallax measured across all or a portion of the image
sensor 124.
[0041] The control subsystem 104 includes one or more processors
126, for example one or more microprocessors (one shown) 126a,
digital signal processors (DSP--one shown) 126b, application
specific integrated circuits (ASIC), programmable gate arrays
(PGA), programmable logic controllers (PLC), or the like. While the
DSP 126b may be considered or provided or packaged as part of the
control subsystem 104, the DSP 126b may in some applications be may
be considered or provided or packaged as part of the camera
subsystem 102.
[0042] The control subsystem 104 includes at least one
non-transitory storage media 130. For example, the control
subsystem 104 may include nonvolatile memory, for instance read
only memory (ROM) or NAND Flash memory 130a. Additionally or
alternatively, all or a portion of the at least one non-transitory
storage media 130 may include volatile memory, for instance dynamic
random access memory (ROM) 130b. The at least one non-transitory
storage media 130 may store one or more computer- or
processor-executable instructions or data, useful in causing the
microprocessor, DSP or other microcontroller to perform dimensional
functions, volumetric functions, volume dimensioning functions,
shipping cost calculation functions, or combinations thereof, for
example by executing the various methods described herein.
[0043] In some instances the at least one non-transitory storage
media 130 may store or otherwise retain a number of distortion
values indicative of the quantitative or qualitative degree of
distortion present in the image data provided by the volume
dimensioning system 100. Such distortion may be present as an
optical distortion, a dimensional distortion, or any other type of
distortion including chromatic distortion that causes deviations
between the image data and the scene within the field of view of
the sensor subsystem 118. In yet other instances, the at least one
non-transitory storage media 130 may store or otherwise retain a
plurality of historical distortion values, such as a plurality of
optical or dimensional distortion values that permit the historical
trending of the optical or dimensional distortion values. Such
historical data can also play a helpful role in demonstrating an
ongoing compliance with one or more corporate, industry, or
regulatory guidelines, best practices, or standards. In at least
some instances, the at least one non-transitory storage media 130
can store or otherwise retain one or more sets of distortion
correction factors useful in reducing or eliminating one or more
forms of distortion present in the image data provided by the
volume dimensioning system 100.
[0044] The optional UI subsystem 106 may include one or more user
interface components which provide information to a user or allow a
user to input information or control operation of the volume
dimensioning system 100.
[0045] For example, the UI subsystem 106 may include a display 132
to visually provide information or control elements to the user.
The display 132 may, for example, take the form of a liquid crystal
display (LCD) panel. The display 132 may, for example, take the
form of a touch sensitive display, allowing the display of user
selectable icons (e.g., virtual keypad or keyboard, graphical user
interface or GUI elements) in addition to the display of
information. The display 132 may be coupled to the control
subsystem 104 via a display driver 134 or similar component. The
display driver 134 may control the presentation of information and
icons on the display 132. The display driver 134 may additionally
process signals indicative of user inputs made via the display
132.
[0046] The UI subsystem 106 may optionally include a physical
keypad or keyboard 136, which allows a user to enter data and
instructions or commands. The physical keypad or keyboard 136 may
be integral to a housing (not shown) of the volume dimensioning
system 100. Alternatively, the optional physical keypad or keyboard
136 may be separate from the housing, communicatively coupled
thereto via a wireless connection or wired connection for instance
a Universal Serial Bus (USB.RTM.) interface.
[0047] The UI subsystem 106 may optionally include a speaker 138 to
provide audible information, cues and/or alerts to a user. The UI
subsystem 106 may optionally include a microphone 140 to receive
spoken information, instructions or commands from a user.
[0048] The communications subsystem 108 may include one or more
wireless communications components and/or one or more wired
communications components to allow communications with devices
external from the volume dimensioning system 100.
[0049] For example the communications subsystem 108 may include one
or more radios (e.g., transmitters, receivers, transceivers) 142
and associated antenna(s) 144. The radio(s) 142 may take any of a
large variety of forms using any of a large variety of
communications protocols, for instance IEEE 802.11, including
WI-FI.RTM., BLUETOOTH.RTM., various cellular protocols for instance
CDMA, TDMA, EDGE.RTM., 3G, 4G, GSM.
[0050] Also for example, the communications subsystem 108 may
include one or more communications ports 146. The communications
ports 146 may take any of a large variety of forms, for example
wired communications ports for instance ETHERNET.RTM. ports,
USB.RTM. ports, FIREWIRE.RTM. ports, THUNDERBOLT.RTM. ports, etc.
The communications ports 146 may even take the form of wireless
ports, for instance an optical or radio frequency transceiver.
[0051] The ADC subsystem 110 may include one or more ADC readers to
perform automatic data collection activities, for instance with
respect to a target object.
[0052] For example, the ADC subsystem 110 may include a radio
frequency identification (RFID) reader or interrogator 148 and
associated antenna 150 to wireless read and/or write to wireless
transponders (e.g., RFID tags or transponders) (not shown). Any of
a large variety of RFID readers or interrogators 148 may be
employed, including fixed or stationary RFID readers or portable or
handheld RFID readers. RFID reader(s) 148 may be used to read
information from a transponder physically or at least proximally
associated with a target object (not shown in FIG. 1). Such
information may, for instance, include recipient information
including an address and/or telephone number, sender information
including an address and/or telephone number, specific handling
instructions (e.g., fragile, keep a give side up, temperature
range, security information). The RFID reader 148 may also write
information to the transponder, for instance information indicative
of a time and/or place at which the transponder was read, creating
a tracking record.
[0053] Also for example, the ADC subsystem 110 may include a
machine-readable symbol reader 152 to wireless read
machine-readable symbols (e.g., one-dimensional or barcode symbols,
two-dimensional or matrix code symbols) (not shown). Any of a large
variety of machine-readable symbol readers 152 may be employed. For
example, such may employ scanner based machine-readable symbol
readers 152 such as those that scan a point of light (e.g., laser)
across a symbol and detector light returned from the symbol, and
decoding information encoded in the symbol. Also for example, such
may employ imager based machine-readable symbol readers 152 such as
those that employ flood illumination (e.g., LEDs) of a symbol,
detect or capture an image of the symbol, and decode information
encoded in the symbol. The machine-readable symbol reader(s) 152
may include fixed or stationary machine-readable symbol readers or
portable or handheld machine-readable symbol readers. The
machine-readable symbol reader(s) 152 may be used to read
information from a machine-readable symbol physically or at least
proximally associated with a target object. Such information may,
for instance, include recipient information including an address
and/or telephone number, sender information including an address
and/or telephone number, specific handling instructions (e.g.,
fragile, keep a give side up, temperature range, security
information).
[0054] While not illustrated, the volume dimensioning system 100
may include a self contained, discrete source of power, for example
one or more chemical battery cells, ultracapacitor cells and/or
fuel cells. While also not illustrated, the volume dimensioning
system 100 may include a recharging circuit, for example to
recharge secondary chemical battery cells. Alternatively or
additionally, the volume dimensioning system 100 may be wired to an
external power source, such as mains, residential or commercial
power.
[0055] FIGS. 2A and 2B illustrate different types of distortion
visible as a deviation between the pattern image data 212, 222
within the respective systems 100 when compared the calibration or
reference pattern 202. The reference pattern 202 is disposed within
the field of view 210 of the at least one image sensor 124 and
comprises alternating squares of white areas 204 and color areas
206.
[0056] The dimensions of the reference pattern 202 are defined,
fixed, and known by the volume dimensioning system 100 prior to
imaging. This allows the volume dimensioning system 100 to analyze
pattern image data 212, 222 containing at least a portion of the
reference pattern 202 to assess or quantify the distortion present
in the image and to generate at least one distortion value
indicative of the distortion. The distortion may be global
throughout the image or may be localized with different portions of
the image exhibiting different types or amounts of distortion.
[0057] FIG. 2A illustrates the effect of an optical distortion that
renders the image with a "pincushion" distortion where the white
and colored squares 204, 206 in the original pattern 202 are
reproduced in the pattern image data 212 as generally diamond
shaped white and colored areas 214, 216, respectively. Although the
pincushion distortion illustrated in FIG. 2A is exaggerated, it can
be appreciated that any such or similar optical distortion may
adversely affect to some degree the volume dimensioning system's
ability to accurately determine dimensional and volumetric data.
Such inaccurate dimensional and volumetric data can adversely
affect the system's ability to provide accurate shipping volumes
and shipping rates to carriers and consumers.
[0058] FIG. 2B illustrates the effect of a dimensional distortion
along a single (horizontal) axis where the white and colored
squares 204, 206 in the reference pattern 202 are reproduced in the
pattern image data 222 as generally rectangular shaped white and
colored areas 224, 226, respectively. Disproportionate compression
of the image data along one axis (e.g., along the x-axis 230 in
FIG. 2B) causes the dimensional distortion seen in the pattern
image data 222. Conversely, disproportionate extension of the image
data along two or more axes may result in both dimensional and
geometric distortion of the reference pattern 202. Although the
dimensional distortion appearing in FIG. 2B is exaggerated, it can
be appreciated that any such or similar dimensional or geometric
distortion can also adversely affect the volume dimensioning
system's ability to accurately determine dimensional and volumetric
data. Such inaccurate dimensional and volumetric data can adversely
affect the system's ability to provide accurate shipping volumes
and shipping rates to carriers and consumers.
[0059] Although shown in two different figures for clarity and ease
of discussion, optical and dimensional distortion, along with other
forms of distortion such as color or chromatic aberration or
distortion, may appear in image data produced by a volume
dimensioning system 100. Such combinations further complicate the
accurate determination of dimensional or volumetric information
therefrom. Uncorrected, such optical and dimensional distortion in
the image can cause the calculation or propagation of erroneous
dimensional information and consequently volumetric information and
volume-based shipping cost information.
[0060] Optical distortion may be present in the image data received
from the sensor subsystem 118 in many forms. Typical forms of
optical distortion present in image data can include radial
distortion, chromatic or spherical aberration, linear distortion,
geometric distortion, and combinations thereof. Such optical
distortion may not necessarily be a consequence of a latent defect
in the sensor subsystem 118 but may be inherent in the design or
manufacture of the optics used to provide the sensor subsystem 118
or characteristic of the image processing hardware, firmware, or
software employed by the volume dimensioning system 100. Such
optical distortion may variously be referred to as pincushion
distortion, barrel distortion, or mustache distortion depending on
the visual appearance of the distortion present in the displayed
pattern image data 212, 222. Regardless of the cause, the presence
of distortion in the image data compromises the ability of the
volume dimensioning system 100 to accurately determine dimensional
or volumetric data for an object. Uncorrected, such optical and
dimensional distortion may adversely impact the accuracy of the
shipping costs provided by the volume dimensioning system 100 and
also may hinder a shipper's ability to schedule and load shipping
containers, trucks, railcars, or the like based on the dimensional
and volumetric data.
[0061] In some instances, optical distortion may be present but
non-uniformly distributed across an image. Such distortion may
result in a portion of an image suffering little or no optical
distortion while other portions of the same image suffer
significant distortion. For example, little optical distortion may
be present in the center portion of an image while all or a portion
of the periphery of the same image may suffer a much greater degree
of optical distortion. In other instances a first type of
distortion may be distributed more-or-less uniformly across the
image while a second type of distortion may be present in one or
more localized areas. In yet other instances, an object of
dimensional interest may lie within only a portion of an optically
distorted image captured by the image sensor. In such instances, it
may be advantageous to locally correct the distortion present in
the area of the image in which the object of dimensional interest
lies. In at least some instances, if the type and extent of such
local distortion present in an image can be assessed or is of a
known type, extent, and/or magnitude, then local dimensional
correction may be possible within the image. The ability to locally
correct distortion present in an image advantageously eliminates
the application of such distortion correction in portions of the
image having where such distortion is not present.
[0062] Although the reference pattern 202 is depicted as a
checkerboard, any number of machine recognizable indicia including
one or more machine-readable symbols, machine-readable patterns,
calibration patterns, calibration targets, calibration points, or
the like may be similarly employed as a tool for assessing the
distortion (e.g., amount, type, location) present in the image
data. Physical parameters associated with the reference pattern 202
can be provided to the volume dimensioning system 100 either as one
or more factory settings (e.g., preloaded values placed into the
read only portion of the non-transitory storage medium) or
communicated to the volume dimensioning system (e.g., via a
network, Bluetooth, or similar connection). All or a portion of
such physical parameters may include color information associated
with the reference pattern 202 including the overall reference
pattern size, the size of the white areas 204, the size of the
colored areas 206, or combinations thereof. All or a portion of
such physical parameters may include the spatial or geometric
relationship between the various white and colored areas 204, 206
in the reference pattern 202. All or a portion of such physical
parameters may include information encoded into one or more regions
or portions of the reference pattern 202 in the form of one or more
machine readable indicia or symbols. Pattern image data 212, 214 is
used by the at least one processor 126 to detect and quantify the
distortion (e.g., optical or dimensional distortion) present in the
image data using the one or more known physical parameters. The
quantity of distortion present may be expressed as at least one
distortion value. In at least some instances, all or a portion of
the reference pattern 202 may be useful in calibrating the volume
dimensioning system 100.
[0063] In at least some instances, the entire electromagnetic
spectrum reflected or otherwise returned from the reference pattern
202 may be used by the at least one processor 126 to determine all
or a portion of the at least one distortion value. In other
instances, only a portion of the electromagnetic spectrum reflected
or otherwise returned from the reference pattern 202 may be used by
the at least one processor 126 to determine the at least one
distortion value. In some instances, the reference pattern 202 may
return pattern image data unique to the electromagnetic spectrum
illuminating the reference pattern 202 (e.g., the pattern image
data returned in a near-ultraviolet spectrum may differ from that
returned in a visible spectrum). Portions of the electromagnetic
spectrum used by the at least one processor 126 may include, but
are not limited to, the near ultraviolet portion of the
electromagnetic spectrum, the near infrared portion of the
electromagnetic spectrum, one or more portions of the visible
electromagnetic spectrum, or any portion of combination
thereof.
[0064] Although the entire reference pattern 202 is shown within
the field of view 210 of the image sensor 124 in both FIGS. 2A and
2B, only a portion of the reference pattern 202 need be within the
field of view 210 of the image sensor 124 to permit the at least
one processor 126 to determine the at least one distortion value
indicative of the distortion present in the pattern image data 212,
222. Additionally, only a portion of the reference pattern 202 need
be within the field of view 210 of the image sensor 124 to permit
the at least one processor 126 to determine a number of sets of
distortion correction factors (e.g., one or more sets of optical or
dimensional distortion correction factors) that are useful in
reducing or eliminating the effect of distortion on the accuracy of
dimensional, volumetric, volume dimensioning or cost data provided
by the volume dimensioning system 100.
[0065] Identification data may in some instances be created,
generated or otherwise provided by the at least one processor 126
and associated with the at least one determined distortion value.
Such identification data may include chronological data such as
data indicative of the date or the time at which the at least one
distortion value was obtained, calculated, or otherwise determined
by the at least one processor 126. Such identification data may
include chronological data such as data indicative of the date or
the time at which one or more sets of distortion correction factors
are determined by the at least one processor 126. Such
identification data may include chronological data associated with
system events (e.g., distortion value determination, distortion
correction determination, system calibration, a change in system
units of accuracy, a change in system configuration, etc.) that are
recommended or required for compliance with one or more corporate,
industry, or regulatory guidelines, best practices, or
standards.
[0066] The determined at least one distortion value along with the
respective associated identification data may be at least partially
stored in the at least one non-transitory storage media 130.
Maintaining a history of the determined at least one distortion
value may advantageously provide the ability for the one or more
processors 126 to predict expected future distortion values and to
detect sudden or unexpected changes in the level or magnitude of
the determined at least one distortion value. Sudden changes in the
at least one distortion value may, for example, indicate an
unexpected change in performance of the volume dimensioning system
100. The ability to predict future expected distortion values may,
for example, be useful in providing a predicted replacement
interval or an expected remaining service life for the volume
dimensioning system 100.
[0067] In at least some instances, the volume dimensioning system
100 can generate an output that includes both identification data
and the associated at least one distortion value either as a
visible output on user interface 132 or as a data output
transmitted via the communication subsystem 108 to an external
device such as a non-transitory data storage location on a local
network or in the cloud or an external display device such as a
printer or similar data output device.
[0068] At least some instances, the at least one processor 126 can
calculate or otherwise determine one or more sets of distortion
correction factors (e.g., one or more sets of optical distortion
factors or one or more sets of dimensional distortion factors)
based in whole or in part on the determined at least one distortion
value. When within a first set of distortion threshold values, the
volume dimensioning system 100 may use the distortion correction
factors to reduce or even eliminate the effects of distortion,
improving the dimensional, volumetric, and resultant shipping cost
calculation capabilities of the volume dimensioning system 100.
[0069] The at least one processor 126 may determine the distortion
correction factors using one or more numerical distortion
correction methods. Numerical distortion correction methods may,
for example, include Brown's distortion model or other similar
mathematical distortion correction methods or schemes. One or more
graphical distortion correction methods may also be used alone or
in cooperation with one or more numerical distortion correction
methods.
[0070] In some instances, the at least one processor 126 may use
the entire electromagnetic spectrum of the image provided by the
sensor subsystem 118 to determine all or a portion of the one or
more distortion correction factors. In other instances, the at
least one processor may use a portion of the electromagnetic
spectrum of the image provided by the sensor subsystem 118 to
determine the one or more distortion correction factors. The use of
sets of distortion correction factors in one or more portions of
the electromagnetic spectrum may in some instances advantageously
provide the ability to partially or completely correct at least a
portion of the chromatic aberration present in the image data
provided by the sensor subsystem 118.
[0071] Dimensional distortion such as that shown in FIG. 2B may
cause the generally square areas of one color (e.g., white 214) and
areas of a second color (e.g., black 216) within the reference
pattern 202 to appear as compressed rectangular or trapezoidal
areas in the pattern image data 222. Such dimensional or geometric
distortion may be evenly or unevenly distributed along one or more
principal axes. For example, in FIG. 2B dimensional distortion may
be present along the x-axis 222, the y-axis 224, or along both
axes. Some or all of the dimensional distortion may be linear or
nonlinear. In addition, although illustrated along two principal
axes, dimensional distortion may be present along a third axis as
well. In the example shown in FIG. 2B, dimensional distortion is
present only along the x-axis 230, wherein each of the respective
areas of one color (e.g., white 214) and areas of the other color
(e.g., black 216) have been reduced in width along the x-axis 230
by approximately 40%. Conversely, little or no dimensional
distortion has occurred along the y-axis 232.
[0072] In at least some instances the distortion present in the
image data may include both optical and dimensional distortion. In
such instances the one or more processors 126 may calculate
multiple distortion values including at least one optical
distortion value indicative of the level of optical distortion
present in the image data and at least one dimensional distortion
value indicative of the level of dimensional distortion present in
the image data. The at least one optical distortion value and the
at least one dimensional distortion value may be stored or
otherwise retained individually within the non-transitory storage
media 130 or alternatively may be combined to provide at least one
combined distortion value reflective of both the optical and
dimensional distortion present in the image data.
[0073] Using one or more calibration parameters of the reference
pattern 202 and based on the determined at least one distortion
value, the one or more processors 126 can determine or otherwise
generate one or more sets of distortion correction factors. Such
sets of distortion correction factors can include one or more sets
of optical distortion correction factors, one or more sets of
dimensional distortion correction factors, or combinations thereof.
The one or more sets of distortion correction factors can be wholly
or partially stored or otherwise retained in the at least one
non-transitory storage media 130. The one or more sets of
distortion correction factors are used by the at least one
processor 126 to reduce or eliminate the effects of distortion
present in the image data on the determined dimensional,
volumetric, volume dimensional, or cost data provided by the volume
dimensioning system 100. Additionally, the one or more sets of
distortion correction factors may be used to by the at least one
processor 126 to correct the image data prior to using the image
data to provide an output on the display 132.
[0074] The volume dimensioning system 100 can determine the at
least one distortion value and one or more sets of distortion
correction factors on a regular or irregular basis. For example, in
some instances, the volume dimensioning system 100 can determine
the at least one distortion value when the reference pattern 202
falls within the field of view of the at least one sensor 124 and
the system 100 is not actively volume dimensioning an object. Such
may occur when the volume dimensioning system 100 is placed in a
defined location for example returned to a cradle or stand. In
other instances, the routine range of motion may bring the
reference pattern 202 within the field of view of the at least one
sensor 124 as the volume dimensioning system is moved or displaced.
For example, the reference pattern 202 may appear in the field of
view of the at least one image sensor 124 when the volume
dimensioning system 110 is moved from a "storage" position or
location to a "ready" position or location, or from a "ready"
position or location to a "storage" position or location. In yet
other instances, the volume dimensioning system 100 may provide one
or more human perceptible indicators or signals that prompt a user
to at least partially align the volume dimensioning system 100 with
the reference pattern 202 to permit the system to perform a
distortion correction or calibration.
[0075] In other instances, determination of the at least one
distortion value and optionally the determination of the at least
one set of distortion correction factors may occur as a portion of
the volume dimensioning system 100 calibration routine. For
example, in some instances, the at least one distortion value may
be determined prior to the performance of a volume dimensioning
system calibration to improve or otherwise enhance the level of
accuracy of the calibration. In some instances, such distortion
correction or calibration routines may be time-based and conducted
at regular or irregular intervals. In other instances, such
distortion correction or calibration routines may be performance
related and conducted based upon one or more measured system
performance parameters. In yet other instances, such distortion
correction or calibration routines may be time and performance
based to comply with one or more corporate, industry, or regulatory
standards, best practices, or guidelines.
[0076] Advantageously, the ability to detect the presence of
distortion present in the image data, to quantify the distortion
using at least one distortion value, to optionally determine one or
more sets of distortion correction factors, and to optionally
incorporate both into a volume dimensioning system calibration
procedure reduces the likelihood of the volume dimensioning system
100 providing erroneous linear, volumetric, or shipping cost
information. Such periodic detection and quantification of
distortion present in the image data may be conducted on an
automatic (i.e., system generated) or manual (i.e., at user
discretion) basis at regular or irregular intervals.
[0077] FIG. 3 shows a volume dimensioning system 100 that has been
received by an exemplary support member 302 such as a stand or
cradle. In at least some instances, at least a portion of a
reference pattern 202 appears within the field of view 210 of the
image sensor 124 when the volume dimensioning system 100 is
received by the support member 302. The support member 302 may
include a base member 304 to increase stability of the support
member. Although depicted in FIG. 3 as supporting a handheld or
portable volume dimensioning system 100, in some instances the
support member 302 may receive only a portion, for example the
sensor subsystem 118, of a larger or even stationary volume
dimensioning system 100. The reference pattern 202 may be formed as
a portion of the base member 304, separate from the base member
304, or as a member that is detachably attached to the base member
304.
[0078] The volume dimensioning system 100 may also include one or
more sensors (not visible in FIG. 3) to detect the presence of the
support member 302. Example sensors may include without limitation,
one or more optical sensors, one or more ultrasonic sensors, one or
more proximity sensors, or similar. Such sensors may provide one or
more input signals to the at least one processor 126 indicating
receipt of the volume dimensioning system 100 by the support member
302. In at least some instances, upon detection of the signal
indicating receipt by the support member 302 the at least one
processor 126 can initiate the capture of image data by the sensor
subsystem 118. Since the reference pattern 202 lies within the
field of view of the at least one image sensor 124, the image data
so acquired may be used to determine at least one distortion value,
calibrate the system 100, calculate one or more sets of distortion
correction factors, or any combination thereof. In some instances,
pattern image data from the sensor subsystem 118 received by the
support member 302 may be wiredly or wirelessly communicated to a
remote volume dimensioning system 100.
[0079] In at least some instances the reference pattern 202 can be
formed on the base 304 or on a rigid or flexible member that is
operably coupled or otherwise attached to the base member 304. The
reference pattern 202 may be formed in different colors, materials,
embossings, debossings, textures, engravings, or similar. In some
instances, the reference pattern 202 may include one or more
inscriptions, logos, designs, trademarked images, or the like. In
at least some instances all or a portion of the reference pattern
202 and the base member 304 may be detached and mounted remotely
from the support member 302. For example, in at least some
instances the reference pattern 202 may be mounted on a vertical
surface such as a wall or similar partition.
[0080] In at least some situations, when the volume dimensioning
system 100 is received by the support member 302 the sensor
subsystem 118 may autonomously provide pattern image data including
at least the portion of the reference pattern 202 to the at least
one processor 126. Autonomous provision of image data by the sensor
subsystem 118 to the at least one processor 126 may occur at
regular or irregular intervals. Autonomous collection of pattern
image data may permit a more frequent updating of the at least one
distortion value or the one or more sets of distortion correction
factors than a manually initiated collection of pattern image data
since such autonomous collection may occur at times when the volume
dimensioning system 100 is not in active use. The pattern image
data so acquired allows the at least one processor 126 to determine
the at least one distortion value using the known reference pattern
202 calibration parameters. Access to pattern image data also
optionally permits the at least one processor 126 to determine the
one or more sets of distortion correction factors. Providing the at
least one processor 126 with the ability to determine the at least
one distortion value and the sets of distortion correction factors
while the volume dimensioning system 100 is not in active use may
advantageously increase the overall accuracy of the dimensional,
volumetric, and cost information provided by the system 100.
[0081] FIG. 4A provides a perspective view of an illustrative
volume dimensioning system 100a where the at least distortion value
within a first threshold permitting the use of a fine unit of
accuracy (e.g., 1 mm depicted in FIG. 4A) to determine the
dimensional, volumetric, and cost data associated with object 402a.
FIG. 4B provides a perspective view of an illustrative volume
dimensioning system 100b now where the at least distortion value is
not within the first threshold permitting the use of a fine unit of
accuracy and, as a consequence, the at least one processor 126 has
autonomously shifted to the use of a coarse unit of accuracy (e.g.,
1 cm depicted in FIG. 4B) to determine the dimensional, volumetric,
and cost data associated with object 402b.
[0082] Although the object 402a is depicted as a cubic solid for
simplicity and ease of illustration, it should be understood that
similar principles as described below will apply to any object
placed within the field of view of the volume dimensioning system
100. Object 402a is illustrated as having actual dimensions of 11.1
cm in length, 6.3 cm in width, and 15.6 cm in height. Such an
object may be representative of a commonly encountered shipping
container such as a cardboard box. Prior to placement of the object
402a in the field of view 210 of the imaging sensor 124, the volume
dimensioning system 100a has determined through the use of a
reference pattern 202 (not shown in FIG. 4A) that the at least one
distortion value associated with the system 100a falls within a
first threshold (e.g., a recalibration threshold) permitting use of
a fine unit of accuracy in dimensioning, volume, and cost
determination. In the example depicted in FIG. 4A, the fine unit of
accuracy is 1 mm. The volume dimensioning system 100a is therefore
able to determine the dimensions of the object 402a to the nearest
millimeter. Thus, the volume dimensioning system 100a is able to
determine the length 406a as 11.1 cm, the width 408a as 6.3 cm, and
the height 410a as 15.6 cm. Using these determined dimensions, the
volume dimensioning system 100a is further able to determine the
volume 412a as 1091 cm.sup.3. Finally, using the determined volume
and assuming a shipping cost of $0.015/cm.sup.3, the volume
dimensioning system 100a can calculate the shipping cost 414a for
object 402a is $16.37.
[0083] Object 402b has dimensions identical to object 402a, 11.1 cm
in length, 6.3 cm in width, and 15.6 cm in height. However, prior
to placement of the object 402b in the field of view 210 of the
imaging sensor 124, the volume dimensioning system 100b has
determined through the use of a reference pattern 202 (not shown in
FIG. 4B) that the at least one distortion value associated with the
system 100b falls outside a first threshold (e.g., a recalibration
threshold) and within a second threshold (e.g., a service required
threshold) which permits the use of a coarse unit of accuracy in
dimensioning, volume determination and cost determination. In the
example depicted in FIG. 4B, the coarse unit of accuracy is 1 cm,
an order of magnitude larger than the fine unit of accuracy used in
FIG. 4A. The volume dimensioning system 100b is therefore only able
to determine the dimensions of the object 402b to the nearest
centimeter. Thus, the volume dimensioning system 100b determines
the length 406b as 11 cm, the width 408b as 6 cm, and the height
410b as 16 cm. Using these determined dimensions, the volume
dimensioning system 100b is further able to determine the volume
412b as 1056 cm.sup.3. Finally, using the determined volume and
assuming a shipping cost of $0.015/cm.sup.3, the volume
dimensioning system 100b is able to calculate the shipping cost
414b for the object 402b is $15.84.
[0084] In at least some instances, the volume dimensioning system
100 can correct distortion present in only a portion of the overall
image. For example, the volume dimensioning system 100 may correct
only the portion of the image containing the object 402. Such local
correction can proceed using one or more correction factors
determined based at least in part on any distortion present in the
portion of the image containing and/or proximate the object 402.
Such local distortion correction factors can be used in a manner
similar to image wide distortion correction factors, for example to
determine the dimensional accuracy achievable with regard to the
object 402 and to determine whether a fine unit of accuracy or a
coarse unit of accuracy should be used in assessing dimensional and
cost information for the object 402.
[0085] FIG. 5 is a flow diagram 500 showing a high level method of
operation of a volume dimensioning system 100. The method starts at
502. At 504 the at least one processor 126 receives pattern image
data from the sensor subsystem 118. In at least some instances,
such pattern image data may be autonomously acquired at regular or
irregular intervals by the volume dimensioning system 100. For
example, pattern image data may be acquired at regular or irregular
intervals when the all or a portion of the volume dimensioning
system 100 is received by the support member 302. In other
instances, such pattern image data may be manually acquired at
regular or irregular intervals by the volume dimensioning system
100. For example, the volume dimensioning system 100 may provide
one or more human perceptible indicators to a user that indicate
the reference pattern 202 should be placed in the field of view of
the at least one sensor 124 to permit the acquisition of pattern
image data for distortion correction or calibration purposes.
[0086] At 506 the at least one processor 126 determines at least
one distortion value using the pattern image data received from the
sensor subsystem 118 at 504. The at least one processor 126 can
determine any number of distortion values, including at least one
of: an optical distortion value, a dimensional distortion value, a
chromatic aberration or distortion value, or combinations thereof.
The distortion values so determined provide a quantitative measure
or assessment of the overall quality of the image data provided by
the sensor subsystem 118. In some instances, all or a portion of
the at least one distortion values determined by the at least one
processor 126 at 506 can be stored or otherwise retained within the
at least one non-transitory storage media 130.
[0087] At 508 the at least one processor 126 compares the
determined at least one distortion value from 506 with a first
distortion threshold. A determined at least one distortion value
falling within the first distortion threshold indicates the
distortion present in the image data provided by the sensor
subsystem 118 is sufficiently small that a fine unit of accuracy
may be used in determining and calculating dimensional, volumetric,
and cost information. Conversely, a determined at least one
distortion value exceeding the first distortion threshold may
indicate the level of distortion present in the image data provided
by the sensor subsystem 118 is sufficiently large that the use of
the fine unit of accuracy is inappropriate and a coarse unit of
accuracy should instead be used to determine and calculate
dimensional, volumetric, and cost information. Such distortion
thresholds may be provided as one or more factory settings or one
or more periodically updated thresholds that are stored or
otherwise retained in the at least one non-transitory storage media
130.
[0088] Advantageously, such adjustments are made autonomously by
the volume dimensioning system 100 without user intervention using
the determined at least one distortion value and a plurality of
distortion thresholds stored or otherwise retained within the
non-transitory storage media 130. For illustrative purposes, Table
1 lists one set of example values that may be associated with
"fine" and "coarse" units of accuracy:
TABLE-US-00001 TABLE 1 Example Units of Accuracy "Fine" Unit
"Coarse" Unit of Accuracy of Accuracy Dimensional Units 1/2 inch 2
inches Volumetric Units 1 in.sup.3 8 in.sup.3 Cost Units $0.01
$0.10
[0089] At 510, if the at least one processor 126 finds the
distortion value determined at 506 is within or less than the first
distortion threshold, the at least one processor 126 can adjust one
or more volume dimensioning system parameters at 512. In at least
some instances, at 512 the one or more processors 126 may calculate
one or more sets of distortion correction factors to reduce or
eliminate the distortion present in the image data provided by the
sensor subsystem 118 using the one or more distortion values
determined at 506. In some instances, adjusting the one or more
volume dimensioning system parameters at 512 may also include
confirming the fine units of accuracy are being used, performing
one or more calibration routines, or combinations thereof.
[0090] At 514 the at least one processor compares the at least one
distortion value determined at 506 with a second distortion
threshold. If at 510 the at least one processor 126 found the at
least one distortion value determined at 506 exceeded the first
distortion threshold at 510, the at least one processor 126 can
compare the determined at least one distortion value with a second
distortion threshold at 514. In at least some instances, distortion
values exceeding the second distortion threshold may indicate the
presence of distortion in the image data provided by the sensor
subsystem 118 that is of a magnitude or severity sufficient to
render the system 100 unusable based on one or more corporate,
industry, or regulatory guidelines, best practices, or
standards.
[0091] Although FIG. 5 illustrates the use of only two distortion
thresholds, any number of distortion thresholds may be similarly
used. Different distortion threshold values may be indicative, for
example, of varying levels or degrees of distortion in the image
data provided by the sensor subsystem 118. Each of the different
levels or degrees of distortion may indicate the need for the
system 100 to use a corresponding unit of accuracy in displaying
dimensional, volumetric or cost information. For example a first
threshold value may be indicative of distortion that allows a unit
of accuracy of 1 mm; a second threshold value may be indicative of
distortion that allows a unit of accuracy of 2 mm; a third
threshold value may be indicative of distortion that allows a unit
of accuracy of 3 mm; a fourth threshold value may be indicative of
distortion that allows a unit of accuracy of 4 mm; a fifth
threshold value may be indicative of distortion that allows a unit
of accuracy of 5 mm; and a sixth threshold value may be indicative
of distortion sufficient to generate a human perceptible "service
required" indicator on the system 100.
[0092] If at 516 the at least one processor 126 finds the at least
one distortion value determined at 506 exceeds or is greater than
the second distortion threshold, the at least one processor 126 can
generate one or more human perceptible outputs indicative of a
"service required" condition at 518. In some instances at 518, one
or more functions or features of the volume dimensioning system
100, for example the costing functionality, may be inhibited if the
distortion value exceeds the second distortion threshold.
[0093] At 520, if the at least one processor 126 found the
distortion value determined at 506 fell between the first and the
second distortion thresholds at 516, the at least one processor 126
can adjust the units of accuracy of the information presented by
the volume dimensioning system 100. In at least some instances, at
least one processor 126 can adjust dimensional, volumetric or cost
information provided by the volume dimensioning system 100 to one
or more coarse units of accuracy. In at least some instances, at
520 the one or more processors 126 may calculate one or more sets
of distortion correction factors to reduce or eliminate the
distortion present in the image data provided by the sensor
subsystem 118 using the one or more distortion values determined at
506. The one or more coarse units of accuracy cause the system 100
to determine, calculate, and display dimensional, volumetric, and
cost data in units of accuracy that are based at least in part on
the capability of the system 100 to resolve such dimensions and
volumes based on the distortion values determined at 506. In at
least some instances, some or all of the units of accuracy may be
based on one or more corporate, industry, or regulatory guidelines,
best practices, or standards. In some instances, for example, the
units of accuracy used by the volume dimensioning system may be
based on the NIST Handbook 44-2012 Chapter 5.58. The method 500
terminates at 522.
[0094] FIG. 6 is a flow diagram 600 showing a low level method of
operation of a volume dimensioning system 100. In particular, the
method 600 illustrates an example method that may be used by the at
least one processor 126 to assess the at least one distortion value
at 506. The method 600 starts at 602. At 604 the at least one
processor 126, using the pattern image data provided by the sensor
subsystem 118, assesses the optical distortion present in the image
data by determining at least one optical distortion value. The at
least one optical distortion value determined at 604 can provide a
quantitative measure of the degree or magnitude of the optical
distortion present in the image data provided by the sensor
subsystem 118. Such a quantitative measure of the optical
distortion present in the image data may be obtained by the at
least one processor 126 using one or more numerical distortion
analysis techniques, graphical distortion analysis techniques, or
combinations thereof.
[0095] At 606 the at least one processor 126 assesses the image
data supplied by the sensor subsystem 118 for dimensional
distortion. The assessment of the dimensional distortion by the at
least one processor 126 determines at least in part at least one
dimensional distortion value. The at least one dimensional
distortion value determined at 606 can provide a quantitative
measure of the degree or magnitude of the dimensional distortion
present in the image data provided by the sensor subsystem 118.
Such a quantitative measure of the dimensional distortion present
in the image data may be obtained by the at least one processor 126
using one or more numerical distortion analysis techniques,
graphical distortion analysis techniques, or combinations thereof.
After the at least one processor 126 has determined at least one
distortion value attributable to either or both optical and
dimensional distortion present in the image data provided by the
sensor subsystem 118, the method 600 concludes at 608.
[0096] FIG. 7 is a flow diagram 700 showing a low level method of
operation of a volume dimensioning system 100. In particular, the
method 700 illustrates an example method that may be used by the at
least one processor 126 to store historical distortion data
including determined distortion values and distortion correction
factors in the non-transitory storage media 130. Such historical
data provides a valuable resource in tracking the performance
history of the volume dimensioning system 100 and in providing a
tool for predicting the future performance of the system 100. In
some instances, collection of such historical data may assist in
compliance with one or more corporate, industry, or regulatory
guidelines, best practices, or standards. Advantageously, since the
determination of distortion values and distortion correction
factors may be performed autonomously by the volume dimensioning
system 100, the presence of such historical data in the
non-transitory storage media 130 provides the system user with
assurance that such distortion detection and correction routines
are being performed by the system 100. The example method to store
historical distortion data begins at 702.
[0097] At 704, the at least one processor 126 can associate one or
more identifiers with the at least one distortion value determined
at 506 or the one or more sets of distortion correction factors
determined at 512 or 520. Any type of logical identifier, including
one or more sequential or chronological identifiers, may be so
associated with the at least one distortion value. The association
of one or more logical identifiers with the at least one distortion
value or the one or more sets of distortion correction factors
permits the retrieval and presentation of such data in an organized
and logical manner. Storage of such historical data may also assist
in compliance with one or more corporate, industry, or regulatory
guidelines, best practices, or standards.
[0098] At 704 the at least one processor 126 can associate one or
more logical identifiers with all or a portion of the distortion
values (i.e., determined at 506) or all or a portion of the
calculated sets of distortion correction factors (i.e., calculated
at 512 or 520). In at least some instances, the one or more logical
indicators can include one or more chronological indicators such as
date and time of determination of the at least one distortion value
or calculation of the set of distortion correction factors by the
at least one processor 126. In some instances, the one or more
logical indicators can include one or more serialized indicators
sequentially assigned by the at least one processor 126 upon
determining the at least one distortion values or calculating the
set of distortion correction factors. Any similar logical
indicators that provide the ability to retrieve, sort, organize, or
display the associated distortion values or distortion correction
factors in a logical manner may be so assigned by the at least one
processor 126.
[0099] At 706, the at least one distortion value or the set of
distortion correction factors and the associated logical identifier
are at least partially stored within a non-transitory storage media
130. In at least some instances, at least a portion of the
non-transitory storage media 130 can include one or more types of
removable media, for example secure digital (SD) storage media,
compact flash (CF) storage media, universal serial bus (USB)
storage media, memory sticks, or the like. The use of such
removable storage media may advantageously permit the transfer of
data such as the stored distortion values and distortion correction
factors to one or more external computing devices equipped with a
comparable removable storage media reader.
[0100] At 708, the stored distortion values or distortion
correction factors are displayed sorted or otherwise arranged or
organized by the associated identifier either on the internal
display device 132 of the volume dimensioning system 100 or an
external display device wiredly or wirelessly accessed by the
system 100 via the communications subsystem 108.
[0101] At 710, the stored distortion values or distortion
correction factors are displayed sorted by the associated
identifier either on the internal display device 132 of the volume
dimensioning system 100 or an external display device wiredly or
wirelessly accessed by the system 100 via the communications
subsystem 108. Additionally, one or more trend lines may be fitted
to the displayed data to provide an indication of the overall rate
of degradation or change in distortion of the image data provided
by the sensor subsystem 118. Such trend data may be useful in
detecting sudden or unexpected changes in the overall level of
image data quality provided by the sensor subsystem 118 and may
advantageously provide an indication of the overall condition of
the sensor subsystem 118.
[0102] At 712, the stored distortion values or distortion
correction factors are displayed sorted by the associated
identifier either on the internal display device 132 of the volume
dimensioning system 100 or an external display device wiredly or
wirelessly accessed by the system 100 via the communications
subsystem 108. Additionally, through the use of one or more trend
lines or similar data analysis techniques, a performance forecast
is provided. Such performance forecasts may identify an expected
date or timeframe in which the image data provided by the sensor
subsystem 118 will no longer fall within an acceptable distortion
threshold. Such data may advantageously indicate or predict an
expected date at which the sensor subsystem 118 or the volume
dimensioning system 100 may require service or replacement. The
method 700 terminates at 714
[0103] The above description of illustrated embodiments, including
what is described in the Abstract, is not intended to be exhaustive
or to limit the embodiments to the precise forms disclosed.
Although specific embodiments of and examples are described herein
for illustrative purposes, various equivalent modifications can be
made without departing from the spirit and scope of the disclosure,
as will be recognized by those skilled in the relevant art. The
teachings provided herein of the various embodiments can be applied
to other automated systems, not necessarily the exemplary volume
dimensioning system generally described above.
[0104] For instance, the foregoing detailed description has set
forth various embodiments of the devices and/or processes via the
use of block diagrams, schematics, and examples. Insofar as such
block diagrams, schematics, and examples contain one or more
functions and/or operations, it will be understood by those skilled
in the art that each function and/or operation within such block
diagrams, flowcharts, or examples can be implemented, individually
and/or collectively, by a wide range of hardware, software,
firmware, or virtually any combination thereof. In one embodiment,
the present subject matter may be implemented via Application
Specific Integrated Circuits (ASICs). However, those skilled in the
art will recognize that the embodiments disclosed herein, in whole
or in part, can be equivalently implemented in standard integrated
circuits, as one or more computer programs executed by one or more
computers (e.g., as one or more programs running on one or more
computer systems), as one or more programs executed by on one or
more controllers (e.g., microcontrollers) as one or more programs
executed by one or more processors (e.g., microprocessors), as
firmware, or as virtually any combination thereof, and that
designing the circuitry and/or writing the code for the software
and or firmware would be well within the skill of one of ordinary
skill in the art in light of the teachings of this disclosure.
[0105] When logic is implemented as software and stored in memory,
logic or information can be stored on any computer-readable medium
for use by or in connection with any processor-related system or
method. In the context of this disclosure, a memory is a
computer-readable medium that is an electronic, magnetic, optical,
or other physical device or means that contains or stores a
computer and/or processor program. Logic and/or the information can
be embodied in any computer-readable medium for use by or in
connection with an instruction execution system, apparatus, or
device, such as a computer-based system, processor-containing
system, or other system that can fetch the instructions from the
instruction execution system, apparatus, or device and execute the
instructions associated with logic and/or information.
[0106] In the context of this specification, a "computer-readable
medium" can be any element that can store the program associated
with logic and/or information for use by or in connection with the
instruction execution system, apparatus, and/or device. The
computer-readable medium can be, for example, but is not limited
to, an electronic, magnetic, optical, electromagnetic, infrared, or
semiconductor system, apparatus or device. More specific examples
(a non-exhaustive list) of the computer readable medium would
include the following: a portable computer diskette (magnetic,
compact flash card, secure digital, or the like), a random access
memory (RAM), a read-only memory (ROM), an erasable programmable
read-only memory (EPROM, EEPROM, or Flash memory), a portable
compact disc read-only memory (CDROM), digital tape, and other
nontransitory media.
[0107] Many of the methods described herein can be performed with
one or more variations. For example, many of the methods may
include additional acts, omit some acts, and/or perform or execute
acts in a different order than as illustrated or described.
[0108] The various embodiments described above can be combined to
provide further embodiments. All of the commonly assigned US patent
application publications, US patent applications, foreign patents,
foreign patent applications and non-patent publications referred to
in this specification and/or listed in the Application Data Sheet,
including but not limited to U.S. provisional patent application
Ser. No. 61/691,093, filed is incorporated herein by reference, in
its entirety. Aspects of the embodiments can be modified, if
necessary, to employ systems, circuits and concepts of the various
patents, applications and publications to provide yet further
embodiments.
[0109] These and other changes can be made to the embodiments in
light of the above-detailed description. In general, in the
following claims, the terms used should not be construed to limit
the claims to the specific embodiments disclosed in the
specification and the claims, but should be construed to include
all possible embodiments along with the full scope of equivalents
to which such claims are entitled. Accordingly, the claims are not
limited by the disclosure.
* * * * *