Detecting When Carts Are Full

When packages for shipment are collected into a cart from a conveyor or chute, a human operator or robot needs to be alerted when the cart is full and ready to be replaced with
an empty one. Typically, photoelectric and ultrasonic sensors have been used for this detection task, but most have a small-diameter spot. This can provide inaccurate readings, because the packages will naturally fall into a pile of unpredictable shape—potentially with peaks and valleys, or with gaps between boxes—which a small sensor spot could easily misinterpret.

The ZMX 3D Sensor has been designed to monitor a wide area. Its three-dimensional field of view and 2.5-meter range ensures that it can accurately detect objects within the full space that the cart occupies. A single ZMX can observe the cart as it fills up with packages and send a notification signal when the cart contents reach a predefined height, regardless of object sizes, angles, or positions. This active monitoring prevents cart overflows.