The present disclosure generally relates to cargo container sensors and more specifically to optical cargo container sensors.
Cargo handling system generally have knowledge of cargo container positions and velocities. Current techniques can detect presence of the cargo container and roughly estimate motion of the cargo container. Various ways to overcome these limitations include the use of lidar or vision systems as inputs to the cargo handling system. Vision systems may use an optical sensor in combination with lenses and focus control. Such systems are complex and fragile in a cargo container environment.
A cargo handling system is disclosed herein. The cargo handling system includes a conveyance surface a power drive unit for moving cargo along the conveyance surface where the power drive unit disposed in the conveyance surface and a cargo detector coupled to the power drive unit. The cargo detector includes an image sensor having a sensing surface, the sensing surface being oriented towards the cargo, a shutter disposed between the image sensor and the cargo, and a pin hole disposed in the shutter.
In various embodiments, the pin hole as a diameter of about 0.1 mm to about 1 mm. In various embodiments, there is a distance between the image sensor and the pin hole, the distance being about 8 mm to about 12 mm.
In various embodiments, the cargo handling system further includes a light source configured to illuminate the cargo. In various embodiments, the cargo detector is disposed within the power drive unit. In various embodiments, the image sensor is a charge-coupled device. In various embodiments, there is a distance between a top surface of the conveyance surface and the pin hole, the distance being about 15 mm to about 50 mm.
Also disclosed herein is a cargo detector. The cargo detector includes an image sensor being oriented toward the cargo, a shutter disposed between the image sensor and the cargo, and a pin hole disposed in the shutter. In various embodiments, the pin hole has a diameter of about 0.1 mm to about 1 mm. In various embodiments, the image sensor is about 8 mm to about 12 mm from the pin hole. In various embodiments, the cargo detector further includes a light source configured to illuminate the cargo.
In various embodiments, the cargo detector further includes a housing for housing the motor, the wheel, and the cargo detector. In various embodiments, the image sensor is a charge-coupled device. In various embodiments, a distance from the cargo to the pin hole is about 15 mm to about 50 mm.
Also disclosed herein is a detector. The detector includes a housing having a first end and an opposing second end, the second end being open, an image sensor disposed in the housing and near the first end, the image sensor configured to capture images through the open second end, a shutter disposed in the housing between the image sensor and the open second end, and a pin hole disposed in the shutter. In various embodiments, the pin hole has a diameter of about 0.1 mm to about 1 mm. In various embodiments, a distance from the image sensor to the pin hole is about 8 mm to about 12 mm.
In various embodiments, the detector further includes a light source coupled to the housing and configured to illuminate a surface exterior to the housing. In various embodiments, a distance from the surface to the pin hole is about 15 mm to about 50 mm. In various embodiments, the image sensor is a charge-coupled device.
The foregoing features and elements may be combined in any combination, without exclusivity, unless expressly indicated herein otherwise. These features and elements as well as the operation of the disclosed embodiments will become more apparent in light of the following description and accompanying drawings.
The subject matter of the present disclosure is particularly pointed out and distinctly claimed in the concluding portion of the specification. A more complete understanding of the present disclosure, however, may best be obtained by referring to the following detailed description and claims in connection with the following drawings. While the drawings illustrate various embodiments employing the principles described herein, the drawings do not limit the scope of the claims.
The following detailed description of various embodiments herein makes reference to the accompanying drawings, which show various embodiments by way of illustration. While these various embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, it should be understood that other embodiments may be realized and that changes may be made without departing from the scope of the disclosure. Thus, the detailed description herein is presented for purposes of illustration only and not of limitation. Furthermore, any reference to singular includes plural embodiments, and any reference to more than one component or step may include a singular embodiment or step. Also, any reference to attached, fixed, connected, or the like may include permanent, removable, temporary, partial, full or any other possible attachment option. Additionally, any reference to without contact (or similar phrases) may also include reduced contact or minimal contact. It should also be understood that unless specifically stated otherwise, references to “a,” “an” or “the” may include one or more than one and that reference to an item in the singular may also include the item in the plural. Further, all ranges may include upper and lower values and all ranges and ratio limits disclosed herein may be combined.
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In various embodiments, the plurality of trays 104 may further support a plurality of power drive units (PDUs) 110, each of which may include one or more drive wheels or rollers 108 that may be actively powered by a motor. In various embodiments, one or more of the plurality of trays 104 is positioned longitudinally along the cargo deck 112—e.g., along the X-direction extending from the forward end to the aft end of the aircraft. In various embodiments, the plurality of conveyance rollers 106 and the one or more drive rollers 108 may be configured to facilitate transport of the ULD 120 in the forward and the aft directions along the conveyance surface 102. During loading and unloading, the ULD 120 may variously contact the one or more drive rollers 108 to provide a motive force for transporting the ULD 120 along the conveyance surface 102. Each of the plurality of PDUs 110 may include an actuator, such as, for example, an electrically operated motor, configured to drive the one or more drive rollers 108 corresponding with each such PDU 110. In various embodiments, the one or more drive rollers 108 may be raised from a lowered position beneath the conveyance surface 102 to an elevated position protruding above the conveyance surface 102 by the corresponding PDU. As used with respect to cargo handling system 100, the term “beneath” may refer to the negative Z-direction, and the term “above” may refer to the positive Z-direction with respect to the conveyance surface 102. In the elevated position, the one or more drive rollers 108 variously contact and drive the ULD 120 that otherwise rides on the plurality of conveyance rollers 106. Other types of PDUs, which can also be used in various embodiments of the present disclosure, may include a drive roller that is held or biased in a position above the conveyance surface by a spring. PDUs as disclosed herein may be any type of electrically powered rollers that may be selectively energized to propel or drive the ULD 120 in a desired direction over the cargo deck 112 of the aircraft. The plurality of trays 104 may further support a plurality of restraint devices 114. In various embodiments, each of the plurality of restraint devices 114 may be configured to rotate downward as the ULD 120 passes over and along the conveyance surface 102. Once the ULD 120 passes over any such one of the plurality of restraint devices 114, such restraint device 114 returns to its upright position, either by a motor driven actuator or a bias member, thereby restraining or preventing the ULD 120 from translating in the opposite direction.
In various embodiments, the cargo handling system 100 may include a system controller 130 in communication with each of the plurality of PDUs 110 via a plurality of channels 132. Each of the plurality of channels 132 may be a data bus, such as, for example, a controller area network (CAN) bus. An operator may selectively control operation of the plurality of PDUs 110 using the system controller 130. In various embodiments, the system controller 130 may be configured to selectively activate or deactivate the plurality of PDUs 110. Thus, the cargo handling system 100 may receive operator input through the system controller 130 to control the plurality of PDUs 110 in order to manipulate movement of the ULD 120 over the conveyance surface 102 and into a desired position on the cargo deck 112. In various embodiments, the system controller 130 may include a general purpose processor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA) or some other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof. The cargo handling system 100 may also include a power source 126 configured to supply power to the plurality of PDUs 110 or to the plurality of restraint devices 114 via one or more power busses 128. The system controller 130 may be complimented by or substituted with an agent-based control system, whereby control of each PDU and associated componentry—e.g., the restraint devices—is performed by individual unit controllers associated with each of the PDUs and configured to communicate between each other.
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In addition, a restraint device 214, such as, for example, one of the plurality of restraint devices 114 described above with reference to
In various embodiments, the PDU 210 may also include a radio frequency identification device or RFID device 246, or similar device, configured to store, transmit or receive information or data—e.g., operational status or location data. Additionally, a ULD sensor 219 may be disposed within the tray 204 and configured to detect the presence of a ULD as the ULD is positioned over or proximate to the PDU 210 or the restraint device 214. In various embodiments, the ULD sensor 219 may include any type of sensor capable of detecting the presence of a ULD. For example, in various embodiments, the ULD sensor 219 may comprise a proximity sensor, a capacitive sensor, a capacitive displacement sensor, a Doppler effect sensor, an eddy-current sensor, a laser rangefinder sensor, a magnetic sensor, an active or passive optical sensor, an active or passive thermal sensor, a photocell sensor, a radar sensor, a sonar sensor, a lidar sensor, an ultrasonic sensor or the like.
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Sensor 306 may be a reflective sensor such as for example, charge-coupled device (CCD) or another type of image sensor. Sensor 306 has a resolution of about 160×240 pixels to about 2560×1920 pixels and more specifically about 320×480 pixels to about 640×480 pixels. Sensor 306 is sized to fit within PDU 210. In various embodiments, sensor 306 is about 1 mm (0.04 inches)×0.75 mm (0.03 inches) to about 8 mm (0.31 inches)×6 mm (0.24 inches) and more specifically about 2 mm (0.08 inches)×1.5 mm (0.06 inches) to about 4 mm (0.16 inches)×3 mm (0.12 inches). Sensor 306 has a read-out speed of about 100 frames/s to about 1000 frames/s and more specifically about 125 frames/s to about 200 frames/s. There is tradeoff between sensor size, sensor resolution, and sensor read-out speed that is balanced when selecting a sensor 306 to be used with detector 300.
Light source 308 may include one or more individual LEDs. In the depicted embodiment, light source 308 is mounted to the side of housing 304. In various embodiments, light source 308 may be mounted to the top, bottom, or side of housing 304. In various embodiments, light source 308 may not be mounted to housing 304 but be located near housing 304. The location of light source 308 may be in any position so long as there is minimal back reflection through housing 304 and received by sensor 306.
Shutter 310 includes a pin hole 314 located in the center of shutter 310. Pin hole 314 has a diameter of about 0.05 mm (0.002 inches) to about 1.5 mm (0.059 inches) and more specifically about 0.1 mm (0.004 inches) to about 1 mm (0.039 inches). Shutter 310, and more specifically pin hole 314, is a distance d1 from sensor 306 (e.g., in the y-direction). Distance d1 is about 5 mm (0.19 inches) to about 20 mm (0.79 inches) and more specifically about 8 mm (0.31 inches) to about 12 mm (0.47 inches). Shutter 310 and pin hole 314 function as a camera obscura, focusing light onto sensor 306 for detecting movement of a cargo container without using expensive and fragile lenses and focusing mechanisms. Light enters housing 304 through opening 312, passes through pin hole 314, and strikes sensor 306. An image may then be captured based on the light striking sensor 306.
In the depicted embodiment, housing 304 has a length L1 along the y-axis that is about double distance d1. In various embodiments, length L1 may be about equal to distance d1. Cargo container is a distance d2 from pin hole 314 as it is moved by PDU 210. Distance d2 may be about 10 mm (0.39 inches) to about 100 mm (3.94 inches) and more specifically about 15 mm (0.59 inches) to about 50 mm (1.97 inches). Pin hole 314 at distance d1 and cargo container at distance d2 allow sensor 306 to detect variations in the surface of cargo container 302. For example, while cargo container 302 may appear smooth there are many small variations in the surface of cargo container such as dings, scratches, discolorations, etc. that may be used to determine whether cargo container 302 is moving and how fast cargo container 302 is moving. Generally, current cargo handling systems, such as cargo handling system 100, are configured to move cargo containers up to about 0.3 m/s (1 foot/s) with future systems being up to about 1 m/s (3.3 feet/s). Detector 300 as described herein is capable of detecting position and motion at the current speeds of cargo container systems as well as with the future speeds cargo container systems.
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Benefits, other advantages, and solutions to problems have been described herein with regard to specific embodiments. Furthermore, the connecting lines shown in the various figures contained herein are intended to represent exemplary functional relationships and/or physical couplings between the various elements. It should be noted that many alternative or additional functional relationships or physical connections may be present in a practical system. However, the benefits, advantages, solutions to problems, and any elements that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as critical, required, or essential features or elements of the disclosure. The scope of the disclosure is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” Moreover, where a phrase similar to “at least one of A, B, or C” is used in the claims, it is intended that the phrase be interpreted to mean that A alone may be present in an embodiment, B alone may be present in an embodiment, C alone may be present in an embodiment, or that any combination of the elements A, B and C may be present in a single embodiment; for example, A and B, A and C, B and C, or A and B and C. Different cross-hatching is used throughout the figures to denote different parts but not necessarily to denote the same or different materials.
Systems, methods and apparatus are provided herein. In the detailed description herein, references to “one embodiment,” “an embodiment,” “various embodiments,” etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described. After reading the description, it will be apparent to one skilled in the relevant art(s) how to implement the disclosure in alternative embodiments.
Numbers, percentages, or other values stated herein are intended to include that value, and also other values that are about or approximately equal to the stated value, as would be appreciated by one of ordinary skill in the art encompassed by various embodiments of the present disclosure. A stated value should therefore be interpreted broadly enough to encompass values that are at least close enough to the stated value to perform a desired function or achieve a desired result. The stated values include at least the variation to be expected in a suitable industrial process, and may include values that are within 10%, within 5%, within 1%, within 0.1%, or within 0.01% of a stated value. Additionally, the terms “substantially,” “about” or “approximately” as used herein represent an amount close to the stated amount that still performs a desired function or achieves a desired result. For example, the term “substantially,” “about” or “approximately” may refer to an amount that is within 10% of, within 5% of, within 1% of, within 0.1% of, and within 0.01% of a stated amount or value.
Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S.C. 112(f) unless the element is expressly recited using the phrase “means for.” As used herein, the terms “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.
Finally, it should be understood that any of the above described concepts can be used alone or in combination with any or all of the other above described concepts. Although various embodiments have been disclosed and described, one of ordinary skill in this art would recognize that certain modifications would come within the scope of this disclosure. Accordingly, the description is not intended to be exhaustive or to limit the principles described or illustrated herein to any precise form. Many modifications and variations are possible in light of the above teaching.