Development of high precision in-motion weight sensor array for non-singulated packages

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One of the most important functions of the automated sorting facility is to measure the size (dimension) and/or the weight of each package for correct pricing. Unlike other sensory devices (i.e. dimensioner, barcode reader and camera), measuring weight needs "singulation" of the object, i.e. each package has to be separated from others so that it can be loaded, individually, on a short section of the conveyor supported by a scale. This causes the weight measurement station to become a bottleneck of flow. Therefore, there has been a strong need among package deliver industries for an innovative way to measure the weight of an individual package while it is moving on a conveyor in a non-singulated and a non-spaced (or random) way. In collaboration with Purolator Inc., the PI (Prof. Soo Jeon) took on the Engage project where he proposed a concept of distributed weight-measuring roller arrays and demonstrated some promising results using the proof-of-concept device. The proposed Engage Plus project aims to capitalize on the success achieved from the development pursued as part of the original Engage project. More specifically, we aim to significantly enhance the accuracy and reliability of the weight measurement cells by suppressing mechanical noise, which is the main technical issue identified during the Engage project. Furthermore, we aim to develop a scaled-up, fully-motorized version of the weight measuring arrays that can operate on multiple packages transported at the actual conveyor speeds. In doing so, we will take the modularization approach, i.e. to configure the sensing part and the actuation part as standardized modules so that, any type of sensor module can be put together with any type of transport modules. If successful, the outcomes of this research will transform the way the transportation and logistics industry run their sorting facilities. Furthermore, the technology holds a potential to make a broad impact to numerous industrial applications that are involved in the use of conveyors. The development of the proposed technology will help Purolator raise their revenue and increase their competitiveness in the global market as they compete with foreign giants such as FeDex or UPS.