Air Jet Array Sorting for Low-Maintenance Material Separation

Solution Overview

Problem

Conventional industrial screens for material separation have large footprints and require high maintenance due to clogging, necessitating a more efficient and flexible method.

Innovation Solution

A system utilizing a series of air jet array sorting devices coordinated by a management control system (MCS) that employs machine learning to identify and divert materials of a designated category using controllable air streams, with quality control mechanisms to refine separation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If industrial screens are used for material separation, then materials can be separated by density and size, but the device occupies large footprint area and requires high maintenance

Engineering Contradiction:

Improveseparation capabilityVSAvoidfootprint

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The patent replaces the mechanical screening system with a pneumatic system using air jets to divert materials. Instead of using physical screens that require large areas and frequent cleaning, the system uses controlled air streams to separate materials based on their aerodynamic properties, significantly reducing the device footprint and maintenance requirements

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention employs pneumatic technology by using arrays of air jets to propel and divert materials into different collection bins. The system controls material separation through variable air pressure and flow rate, eliminating the need for large mechanical screens and reducing maintenance burden

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Reliability

If industrial screens are used for material separation, then materials can be separated by density and size, but the device requires regular cleaning due to clogging

Engineering Contradiction:

Improveseparation capabilityVSAvoidmaintenance burden

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The patent replaces the mechanical screening system with a pneumatic system using air jets to divert materials. Instead of using physical screens that require large areas and frequent cleaning, the system uses controlled air streams to separate materials based on their aerodynamic properties, significantly reducing the device footprint and maintenance requirements

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system dynamically adjusts air pressure and flow rate parameters to optimize separation efficiency for different material types. By varying these parameters, the system can handle diverse materials without clogging, eliminating the need for regular cleaning and maintenance

Inventive Principle:

Principle #35Parameter changes

3Reliability

If conventional screening methods are used, then material separation can be achieved, but the process lacks flexibility in adapting to material variations

Engineering Contradiction:

Improveseparation efficiencyVSAvoidflexibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent implements a dynamic control system that adjusts air jet parameters in real-time based on material characteristics. The system can adapt to varying material types, sizes, and densities by modifying air pressure and flow rate, providing high flexibility and versatility while maintaining separation efficiency

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system dynamically adjusts air pressure and flow rate parameters to optimize separation efficiency for different material types. By varying these parameters, the system can handle diverse materials without clogging, eliminating the need for regular cleaning and maintenance

Inventive Principle:

Principle #35Parameter changes

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

Enhances separation efficiency by dynamically adapting to material variations and optimizing load balancing, reducing maintenance needs while improving precision and scalability.

Implementation Method 1

a first sorting device in the series is caused to perform a first action comprising a diverting action on the subset of objects... by firing a controllable area of a two-dimensional air space as the target object falls off the end of a conveyor

Methodology Applied

Scientific EffectCompressed air stream: Jet

Implementation Method 2

The coordination engine is configured to monitor respective firing activities over time corresponding to the plurality of sorting devices and to load balance future utilization among the plurality of sorting devices

Methodology Applied

Scientific EffectLoad balancing:

Data Source

PatentUS12420310B2Separation of materials using sorting devices

Publication Date: 2025.09.23 AMP ROBOTICS CORP

AI summary

Separation of materials using sorting devices is disclosed, including: receiving image data from sensors, wherein the image data corresponds to a set of objects being transported through a base sorting line; determining a subset of objects from the set of objects that are associated with a designated category based on the image data; sending a first set of data to a first sorting device to perform a diverting action on the subset of objects, wherein the first sorting device and a second sorting device are located along the base sorting line, wherein each of the first and second sorting devices is configured to perform diverting actions to separate materials associated with the designated category off from the base sorting line; and sending a second set of data to the second sorting device to perform a second action, wherein the second action is determined based on the image data.