Bulk Material Sorting via Vibration Conveyor and Roller Trajectory Control
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Solution Overview
Problem
Existing bulk material sorting technologies are limited in detecting defects within the bulk material, particularly in opaque pellets, and suffer from significant trajectory scattering, making comprehensive 100% inspection challenging.
Innovation Solution
A device and method utilizing a vibration conveyor system followed by a rotationally driven roller or a curved section to control the trajectory of bulk material, ensuring precise and comprehensive inspection by minimizing scattering and enabling detection of internal defects using a combination of optical and X-ray detectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a vibration conveyor device is used to convey bulk material, then the bulk material can be transported and inspected, but significant trajectory scattering occurs making precise inspection difficult
Solution Approach 1:
The patent employs a curved trajectory section (S-bend) in the conveyor system to redirect bulk material. This curved geometry allows for smooth transition and control of material trajectory, reducing scattering while maintaining conveyance efficiency. The S-bend design enables precise positioning of material at the inspection point.
Solution Approach 2:
The conveyor system is divided into distinct functional sections: initial conveyance section, curved trajectory section, inspection section, and sorting section. This segmentation allows each section to be optimized independently, with the curved section specifically designed to control trajectory while other sections handle material flow and inspection.
2Measurement precision
If optical detector devices are used to examine bulk material, then surface contaminants can be detected, but internal defects in opaque pellets cannot be detected
Solution Approach 1:
The inspection system integrates multiple detection methods (optical detection and X-ray detection) into a single universal inspection station. This multi-functional approach enables the system to detect both surface contaminants (via optical) and internal defects (via X-ray), eliminating the limitation of single-method detection.
Solution Approach 2:
The patent combines optical detector devices and X-ray detector devices in close proximity to examine bulk material simultaneously. The optical detectors capture surface information while X-ray detectors penetrate to reveal internal structure, creating a comprehensive inspection capability that merges the strengths of both detection methods.
3Reliability
If a 100% inspection of bulk material is implemented, then all defects can be detected, but the complexity and cost of the sorting device increases
Solution Approach 1:
The system uses the bulk material's own trajectory and flow characteristics to its advantage. The curved conveyor section naturally positions material for optimal inspection without requiring complex positioning mechanisms. Material is conveyed and oriented passively through gravity and conveyor geometry, reducing the need for active control systems.
Solution Approach 2:
The patent replaces complex mechanical sorting mechanisms with a more streamlined system. Instead of using elaborate mechanical arms or actuators to manipulate each piece of material, the system uses the conveyor's curved trajectory to naturally guide material through the inspection zone, allowing detectors to examine material as it passes by in a controlled flow.
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
Achieves a high-resolution, 100% inspection of bulk material with reduced scattering, allowing for the reliable detection of both surface and internal defects, enhancing the accuracy and precision of the sorting process.
Implementation Method 1
a vibration conveyor device and a feed device which feeds bulk material to the vibration conveyor device
Implementation Method 2
the end of the vibrating conveyor device is followed by a rotationally driven roller, onto which the bulk material conveyed via the end of the vibrating conveyor device reaches and which the bulk material is conveyed with a Rotation of the role promotes predetermined trajectory towards the first exit
Implementation Method 3
at least one detector device which is designed to examine the bulk material conveyed by the vibrating conveyor device for defects
Implementation Method 4
the at least one X-ray source radiates through the bulk material on the vibrating conveyor device and the at least one X-ray sensor radiating through the bulk material is detected
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to an apparatus for sorting bulk material, in particular pellets, comprising a vibration conveyor and a feed device, which feeds bulk material to the vibration conveyor, further comprising a first exit and a second exit, wherein the first exit is arranged such that the bulk material conveyed over one end of the vibration conveyor drops into the first exit, further comprising at least one detector device, by means of which the bulk material conveyed by the vibration conveyor is examined for defects, wherein the detector device comprises at least one X-ray detector device having at least one X-ray source and at least one X-ray sensor, and wherein the detector device comprises at least one optical detector device operating in the visible wavelength range, and/or at least one detector device operating in the infrared wavelength range, and having at least one optical radiation source and at least one optical sensor, wherein the apparatus also comprises a separating-out device, by means of which bulk material conveyed over the end of the vibration conveyor and detected as being defective by the detector device has its trajectory influenced such that the bulk material detected as being defective drops into the second exit, wherein the end of the vibration conveyor is adjoined by a rotationally driven roller, onto which the bulk material conveyed over the end of the vibration conveyor passes and which conveys the bulk material, over a trajectory predetermined by the rotation of the roller, in the direction of the first exit. The invention also relates to a corresponding method. x