Book Block Sorting With Optical Tag Reading
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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, which existing automation solutions have not adequately addressed.
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 receptacles based on identification tags, and includes conveyors and readers to manage the flow and orientation of book blocks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual sorting is used, then device complexity is low, but productivity is low and manufacturing precision is low
Solution Approach 1:
The patent replaces manual mechanical sorting with an automated system that uses optical readers to detect identification tags on book blocks, control units to process sorting information, and inserting devices to automatically place book blocks into receptacles. This substitution of mechanical manual operations with automated optical and control-based systems resolves the contradiction by achieving high productivity while managing device complexity through modular design.
Solution Approach 2:
The sorting system is designed to automatically read identification tags, process sorting information, and execute sorting actions without continuous human intervention. The system serves itself by using the identification tags on book blocks to automatically determine sorting destinations and executing the sorting process autonomously, thereby increasing productivity while reducing the need for complex manual control systems.
2Manufacturing precision
If manual sorting is used, then device complexity is low, but manufacturing precision is low
Solution Approach 1:
The patent replaces imprecise manual sorting with an automated optical reading system that detects identification tags on book blocks, ensuring accurate reading of sorting information. The control unit processes this information precisely to determine correct receptacle assignments, and inserting devices execute precise physical placement. This automated precision resolves the contradiction by achieving high manufacturing precision through controlled mechanical and optical systems rather than human operators.
Solution Approach 2:
The system uses identification tags on book blocks as feedback signals that contain sorting information. The optical readers continuously scan and read these tags, providing real-time feedback to the control unit about the current book block's sorting requirements. This feedback mechanism enables precise sorting decisions and automatic correction of any deviations, achieving high manufacturing precision through information feedback rather than complex manual judgment.
3Productivity
If automation is introduced, then productivity increases, but device complexity increases
Solution Approach 1:
The patent divides the sorting system into distinct functional segments: optical reading devices for detecting identification tags, control units for processing sorting information, inserting devices for physical placement, and receptacles for storage. This segmentation allows each component to perform its specific function independently, simplifying the overall system architecture while maintaining high productivity through coordinated operation of the modular components.
Solution Approach 2:
The control unit serves multiple functions: it receives sorting information from optical readers, processes the sorting data, determines target receptacles, and coordinates the inserting devices. This multi-functionality reduces the need for separate dedicated components for each task, thereby increasing productivity while managing device complexity through consolidation of control functions.
Data Source
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AI summary
A sorting device (10) for sorting book blocks (50) is described, the sorting device comprising a filling station (1) for sorting one or more book blocks into receptacles (51.1, 51.2, 51.3), a first input conveyor (1.1) configured to feed book blocks to the filling station (1), a second input conveyor (1.2) configured to feed empty receptacles (51.1) to the filling station, a first output conveyor (1.3) configured to transfer full receptacles (51.3) away from the filling station, the filling station comprising a plurality of inserting devices (14) configured to insert the one or more book blocks into the receptacles, wherein the sorting device further comprises a control device (20) 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.