Intelligrated Headquarters, LLC

Feng Zhang

Sriram Pavan Tankasala

Matthew R Wicks

Karthikeyan Yuvaraj

Benjamin E Nilson

The present disclosure relates to a method and system for calibrating a carton detection system. The method includes receiving a three-dimensional (3D) point cloud of a calibration object, determining a 3D target pose of the calibration object by comparing the 3D point cloud to a point cloud template, receiving a two-dimensional (2D) optical image of the calibration object, identifying one or more markers of the calibration object based on the 2D optical image, determining a marker pose for each of the one or more markers based on the 2D optical image, determining a 2D target pose based on the marker pose for each of the one or more markers, generating a transformation matrix based on the 3D target pose and the 2D target pose, and calibrating the carton detection system based on the transformation matrix.

Vision calibration system for robotic carton unloading

Robotic carton loader or unloader incorporates three-dimensional (3D) and two-dimensional (2D) sensors to detect respectively a 3D point cloud and a 2D image of a carton pile within transportation carrier such as a truck trailer or shipping container. Edge detection is performed using the 3D point cloud, discarding segments that are two small to be part of a product such as a carton. Segments that are too large to correspond to a carton are 2D image processed to detect additional edges. Results from 3D and 2D edge detection are converted in a calibrated 3D space of the material carton loader or unloader to perform one of loading or unloading of the transportation carrier. Image processing can also detect jamming of products sequence from individually controllable zones of a conveyor of the robotic carton loader or unloader for singulated unloading.

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St. Louis, MO, United States of America

Feng Zhang