Adaptable Inspection Unit for Processing Lines
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Solution Overview
Problem
Existing processing lines, such as conveyors, are not adaptable to work with improved inspection and sorting devices, leading to inefficiencies in quality inspection and sorting processes, particularly in detecting defects in items like tree nuts and pharmaceutical pills, which require advanced and automated systems for accurate and rapid defect detection.
Innovation Solution
An adaptable inspection unit and sorter unit are developed, equipped with an attachment mechanism, inspection sensors, data ports, and processor circuits, allowing for attachment to processing lines and communication with sorting devices to perform automated inspections and sorting using various sensors and sorting methods, such as vacuum systems or mechanical gates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If existing processing lines are used without modification, then device complexity is reduced, but adaptability to improved inspection and sorting devices is poor
Solution Approach 1:
The patent creates a universal interface system that enables existing processing lines to work with multiple types of improved inspection and sorting devices. The interface includes standardized mechanical mounting structures, electrical power connections, and data communication ports that provide multi-functional compatibility across different device types while maintaining the original processing line configuration.
2Measurement precision
If automated inspection and sorting devices are added to existing processing lines, then inspection quality and defect detection accuracy are improved, but device complexity increases
Solution Approach 1:
The patent segments the inspection and sorting functions into separate modular units that can be independently attached to the processing line. The inspection device module captures and analyzes product characteristics, while the sorting device module executes sorting actions based on inspection results. This segmentation allows high-precision detection capabilities to be added without requiring complete system redesign, thereby improving defect detection accuracy while managing complexity through modularity.
3Productivity
If manual inspection and sorting processes are used, then device complexity is reduced, but productivity and throughput are limited
Solution Approach 1:
The patent replaces manual mechanical inspection and sorting operations with automated electronic systems. Inspection is performed using optical sensors, cameras, and image processing algorithms that automatically detect defects and measure product characteristics. Sorting is automated using actuators and control systems that respond to inspection data in real-time. This substitution dramatically increases throughput capacity while the modular interface design keeps the added complexity manageable.
4Reliability
If advanced inspection devices are integrated into processing lines, then reliability of quality inspection is improved, but ease of operation deteriorates due to increased complexity
Solution Approach 1:
The patent implements self-service functionality where the inspection and sorting system automatically calibrates itself, performs self-diagnosis, and adjusts operational parameters based on real-time feedback. The system includes automatic reference target detection for calibration, built-in error detection and correction mechanisms, and adaptive algorithms that learn from inspection data to improve performance over time. This self-service capability maintains high inspection reliability while reducing the operational burden on users.
Data Source
AI summary
A method for generating a quality inspection data block for a distributed ledger includes: determining an identification code associated with a sample to be inspected, inspecting the sample and thereby generating quality inspection data associated with the sample, and after completion of the inspecting of the sample combining the identification code and the quality inspection data into the quality inspection data block. The method also includes adding the quality inspection data block to the distributed ledger. An inspector including a sensor that senses a characteristic of a sample, a memory that stores sensor output data, and a processor configured to: determine an identification code associated with a sample to be inspected, generate quality inspection data based on the sensor output data, and combine the identification code and the quality inspection data into a quality inspection data block. In one example, the inspector is an in-flight 3D inspector.