Air Blast Diverter for Accurate Object Counting
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Solution Overview
Problem
Conventional imaging systems for counting and inspecting objects, such as those using high-speed cameras and mechanical dividers, often fail to achieve exact counting due to the high volume of objects falling off a chute and the time required for mechanical dividers to change positions, leading to slight discrepancies in the number of objects in containers.
Innovation Solution
A system utilizing a controller, high-speed cameras, and air blast or mechanical diverters to manage the flow of objects between multiple receiving locations, ensuring accurate counting by activating diverters based on target counts and using air blasts to correct misdirection during mechanical divider transitions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a mechanical divider is used to divert objects between containers, then the system can handle high-volume object flows, but the time required for the mechanical divider to change positions causes counting inaccuracies
Solution Approach 1:
The patent replaces the mechanical divider system with an air blast diverter system that uses compressed air to divert objects. This substitution eliminates the mechanical inertia and switching time problems, allowing for rapid, precise diversion of objects to achieve accurate counting while maintaining high-volume handling capability
Solution Approach 2:
The patent employs pneumatic actuators and air blast diverters to control object flow direction. The pneumatic system provides rapid response times and precise control, enabling the system to accurately direct individual objects or streams of objects to the correct container without the delays inherent in mechanical divider systems
2Measurement precision
If the mechanical divider switches positions quickly to maintain exact counting, then count accuracy improves, but the high volume of parts causes the containers to reach target counts with slight discrepancies
Solution Approach 1:
By replacing the mechanical divider with an air blast diverter system, the patent achieves both rapid response for accurate counting and high-speed operation for efficient filling. The pneumatic system can quickly adjust to divert objects without the mechanical constraints that previously forced a trade-off between accuracy and speed
3Measurement precision
If air blast diverters are used to correct misdirection during transitions, then counting precision is maintained, but system complexity increases
Solution Approach 1:
The patent replaces a complex mechanical divider system with a simpler pneumatic air blast diverter system. While pneumatic components are introduced, the overall system complexity is reduced by eliminating mechanical moving parts, switches, and the inertia-associated control complexity of mechanical dividers
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system ensures precise count separation and distribution of objects into target containers, minimizing errors and achieving exact counting even during high-volume object flows by dynamically adjusting diverter positions and using air blasts to maintain accurate segregation.
Implementation Method 1
an air blast diverter adapted to divert all objects in the stream of falling objects such that the stream of falling objects is received at the second location
Data Source
AI summary
A system for count separation of objects comprises a controller, cameras adapted to detect each individual object in a stream of falling objects such that the controller can count the objects, a first receiving location adapted to directly receive the stream of falling objects, a second receiving location adapted to receive objects diverted from the stream of falling objects or to receive the stream of falling objects when the stream of falling objects is diverted from the first receiving location; a mechanical diverter having (a) a first position to not divert the stream of falling objects from the first receiving location and (b) a second position in to divert the stream of falling objects to the second receiving location, and an air blast diverter adapted (a) to divert specific objects or the stream of falling objects to the second location.