Automated Small Object Sorting System with Vision-Guided Extraction
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Solution Overview
Problem
The sorting of small objects such as seeds, pharmaceutical tablets, or small electrical components is cumbersome, time-consuming, and prone to human error due to the manual nature of the process.
Innovation Solution
An automated system and method for sorting small objects, which includes a docking station, an automated tray removal and positioning subsystem, a collection assembly positioning subsystem, and an object extraction subsystem, allowing for the robotic sorting and deposition of objects based on specific attributes into designated receptacles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual sorting is used, then the process is simple to operate, but it is time-consuming and prone to human error
Solution Approach 1:
The system uses vision sensors and automated decision-making algorithms to enable the sorting system to identify and categorize objects autonomously without human intervention, thereby improving reliability while managing complexity through self-service automation
Solution Approach 2:
The patent replaces manual mechanical sorting with an automated system combining vision sensors, computer processing, and robotic manipulation, substituting human cognitive and physical functions with mechanical and computational systems to eliminate human error
2Productivity
If manual sorting is used, then the equipment is simple, but the sorting speed is slow
Solution Approach 1:
The system implements continuous automated operation where vision sensors continuously capture images, the processor continuously analyzes object attributes, and the robotic arm continuously transfers objects, eliminating idle time and maintaining constant productive action to increase sorting speed
Solution Approach 2:
The patent extracts the cognitive and manual labor functions from the sorting process, isolating them as separate automated subsystems (vision sensing, image processing, robotic manipulation) that can operate independently and in parallel to accelerate the overall sorting speed
3Manufacturing precision
If automated extraction is used, then the sorting precision is improved, but the device complexity increases
Solution Approach 1:
The patent introduces a vision sensor system as an intermediary between the objects to be sorted and the robotic arm, providing precise spatial and attribute information that enables accurate object identification and placement without requiring complex direct control mechanisms
Solution Approach 2:
The system creates a digital copy or representation of the physical objects through image capture and processing, allowing the system to analyze and plan sorting operations based on this virtual model, thereby achieving precision without direct physical manipulation complexity
Data Source
AI summary
In various embodiments, a small object sorting system includes an object tray cart docking station configured to dock an object tray cart here within. The system additionally includes an automated tray removal and positioning subsystem configured to remove an object tray from the object tray cart, selectively position the tray such that selected small objects can be extracted therefrom, and replace the object tray into the object tray cart. Furthermore, the system includes an automated collection assembly positioning subsystem configured to selectively position a collection assembly such that the selected extracted small objects can be deposited into selected object receptacles, and an automated object extraction subsystem configured to extract the selected small objects and deposit each extracted small object into the selected object receptacles.