Automated Card Sorting Apparatus with Tray Capacity Verification

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Solution Overview

Problem

The production of collectible cards is labor-intensive and prone to errors due to manual handling, which affects quality control and efficiency in separating and sorting different card types.

Innovation Solution

An automated apparatus that includes a processor, printing press, cutter, pack stacker, pack separator, verifier, and loader, which separates, verifies, and sorts cards into designated trays based on type, reducing manual handling and ensuring quality by using image recognition for verification and alerting operators when trays are full.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual handling is used for separating and sorting cards, then flexibility in operation is maintained, but labor intensity increases and quality control deteriorates

Engineering Contradiction:

Improvemanual handling flexibilityVSAvoidquality control

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent replaces manual mechanical handling with an automated system comprising a conveyor belt, card separator, and sorting mechanism. The card separator automatically divides cards into stacks based on predetermined criteria, and the sorting mechanism places cards into appropriate trays, eliminating manual labor while maintaining operational control through automated decision-making systems.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system enables self-service operation where the card processing apparatus autonomously performs separation, verification, and sorting functions without continuous human intervention. The automated verification system checks card characteristics and directs cards to appropriate trays independently, reducing reliance on manual quality control while improving consistency.

Inventive Principle:

Principle #25Self-service

2Productivity

If automated separation and sorting is implemented, then productivity increases and quality control improves, but device complexity increases

Engineering Contradiction:

Improveproduction efficiencyVSAvoidapparatus complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent divides the card processing system into distinct functional modules: a card separator that divides cards into individual stacks, a verification system that checks card characteristics, and a sorting mechanism that distributes cards to trays. This segmentation allows each component to perform its specific function efficiently while maintaining overall system manageability and productivity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The automated apparatus integrates multiple functions into a single system: the card separator simultaneously performs separation and initial sorting, the verification system checks both card authenticity and quality, and the sorting mechanism distributes cards to multiple tray types. This multi-functionality increases productivity while consolidating device complexity into a unified automated platform.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Device complexity

If manual sorting is used, then device complexity remains low, but production errors increase and labor intensity increases

Engineering Contradiction:

Improvesystem simplicityVSAvoidproduction accuracy

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent incorporates a verification system that provides feedback on card characteristics before sorting. The system verifies card authenticity, checks for defects, and confirms proper stacking, then uses this feedback information to direct cards to appropriate trays. This feedback loop ensures high production accuracy while maintaining automated operation with relatively simple device architecture.

Inventive Principle:

Principle #23Feedback

4Reliability

If automated verification and sorting is implemented, then quality control improves and production errors decrease, but loss of time in setup and configuration occurs

Engineering Contradiction:

Improvequality assuranceVSAvoidsetup time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent configures the card separator and sorting mechanism with predetermined sorting criteria and tray assignments before production begins. The system is pre-programmed with card types, tray destinations, and verification parameters, allowing automated verification and sorting to proceed immediately without time-consuming setup during operation, thus maintaining high quality assurance while minimizing setup time loss.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS11779961B2System for assembling cards in trays

Publication Date: 2023.10.10 R R DONNELLEY & SONS CO

AI summary

A system for assembling cards in trays includes a pack stacker that stacks cards, a pack separator, a tray for receiving cards, and a processor. The processor is programmed to determine a number of cards in the tray, operate the pack stacker to assemble a plurality of cards into a stack, determine whether the plurality of cards can be accommodated in the tray together with the number of cards and, if so, transfer the stack to the tray. The processor is also programmed to operate the pack separator to separate the stack of cards into a sub-stack if the processor determines that the plurality of cards cannot be accommodated in the tray together with the number of cards wherein the sub-stack has less than the plurality of cards and transfer the sub-stack to the tray.