Book Block Sorting Control for Accurate Receptacle Filling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manual sorting of book blocks at the end of a book production line is inefficient and inaccurate due to the variety of book blocks produced for different orders and categories, making automation of this step challenging.
Innovation Solution
A sorting device with a control device that receives sorting information from book blocks, uses inserting devices to automate the sorting process by directing book blocks into specific receptacles based on identification tags, and includes conveyors and readers to manage the flow of book blocks and receptacles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual sorting is used, then device complexity is reduced, but productivity and sorting accuracy deteriorate
Solution Approach 1:
The patent replaces manual mechanical sorting operations with an automated control system that uses electronic identification tags and computer-controlled inserting devices. The control device receives sorting information from identification tags and automatically directs book blocks to the correct receptacles, eliminating manual intervention while maintaining system organization through modular design.
Solution Approach 2:
The sorting system performs self-service by automatically reading identification tags on book blocks and autonomously directing them to the correct receptacles without human intervention. The control device processes sorting information and controls the inserting devices independently, enabling the system to sort book blocks based on their own identification characteristics.
2Manufacturing precision
If manual sorting is used, then device complexity is reduced, but manufacturing precision deteriorates
Solution Approach 1:
The patent replaces imprecise manual sorting with an automated optical/electronic identification system that reads sorting information from identification tags and uses computer-controlled mechanisms to place book blocks in correct receptacles, ensuring high sorting accuracy through digital control rather than human judgment.
Solution Approach 2:
The control device receives real-time sorting information from identification tags on book blocks and uses this feedback to automatically adjust the inserting devices, ensuring that each book block is placed in the correct receptacle based on its identified characteristics, thereby maintaining high sorting precision.
3Productivity
If automation is implemented, then productivity improves, but device complexity increases
Solution Approach 1:
The patent segments the sorting system into distinct functional modules: identification tags on book blocks, a control device that processes sorting information, and separate inserting devices for each receptacle. This modular segmentation allows each component to perform its specific function independently, improving productivity while keeping the overall system complexity manageable through clear functional separation.
Solution Approach 2:
The control device serves multiple functions by processing sorting information from identification tags, determining target receptacles, and controlling multiple inserting devices. This multi-functionality consolidates control operations into a single unit, improving productivity through centralized automation while avoiding the need for separate complex control systems for each sorting function.
Data Source
AI summary
A sorting device for sorting book blocks is described, the sorting device having a filling station for sorting one or more book blocks into receptacles, a first input conveyor configured to feed book blocks to the filling station, a second input conveyor configured to feed empty receptacles to the filling station, a first output conveyor configured to transfer full receptacles away from the filling station, the filling station comprising a plurality of inserting devices configured to insert the one or more book blocks into the receptacles, wherein the sorting device further includes a control device configured to receive sorting information of the one or more book blocks and to control the inserting devices to sort the one or more book blocks into the receptacles using the sorting information.