Channel Guide Plate Sorting System for Occlusion and Precision
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Solution Overview
Problem
Existing bulk object sorting systems face issues such as occlusion, limited information capture, customization requirements, and imprecision in object ejection, leading to reduced throughput and sorting accuracy.
Innovation Solution
A guide plate with channels featuring a first aperture for optical measurement and a second aperture for calculating conveying velocity, allowing precise timing for object ejection based on measured properties using an ejector unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rotating drum with pockets is used for sorting objects, then objects can be lifted and characterized, but openings may be occluded by stuck objects rendering pockets useless
Solution Approach 1:
The system divides the bulk object flow into separate parallel channels, with each channel handling one or few objects at a time. This segmentation prevents objects from blocking each other's paths and eliminates the occlusion problem inherent in rotating drum pockets, ensuring continuous reliable operation of each channel.
Solution Approach 2:
The patent replaces the mechanical rotating drum system with a stationary guide plate and controlled ejection mechanism. Objects move through fixed channels rather than being carried by rotating pockets, eliminating the mechanical complexity and reliability issues of the drum system while maintaining sorting functionality.
2Loss of information
If only a limited opening size is used in drum pockets, then the system structure is simple, but the magnitude of information obtained from objects is limited
Solution Approach 1:
The system transitions from measuring objects through limited 2D openings in drum pockets to capturing objects in a planar measurement zone within channels. This dimensional change allows optical sensors to capture comprehensive surface information across the entire object width without being constrained by small opening sizes.
Solution Approach 2:
The channel structure serves multiple functions simultaneously: it guides objects through the measurement zone, positions them for optical characterization, and controls their movement timing. This multi-functionality eliminates the need for separate components, maximizing information capture while maintaining structural simplicity.
3Measurement precision
If a bulk stream of objects drops over a ledge for sorting, then the system structure is simple, but ejection imprecision causes mixed properties in ejected groups
Solution Approach 1:
The system segments the bulk object stream into individual channels, isolating objects from one another during measurement and ejection. This segmentation enables precise control of each object's ejection timing based on its specific characteristics, achieving high sorting accuracy without the mixed-property ejection problem of bulk stream systems.
Solution Approach 2:
The system uses optical sensors to measure object properties within the channel and provides feedback to control the ejection timing. This closed-loop feedback mechanism ensures that each object is ejected at the precise moment based on its measured characteristics, achieving high sorting accuracy while maintaining manageable system complexity through automated control.
4Measurement precision
If drum pockets are customized after object size in three dimensions, then sorting accuracy is improved, but the device complexity and customization requirements increase
Solution Approach 1:
The system replaces fixed, customized drum pockets with flexible channel configurations that can be easily adjusted or reconfigured. The guide plate with channels provides adaptable object guidance without requiring complex three-dimensional customization, achieving sorting accuracy through controlled object positioning rather than custom-fitted pockets.
Solution Approach 2:
The patent extracts the essential sorting function from the complex rotating drum structure and implements it through simpler stationary channels. By removing the rotating mechanism and customized pockets, the system achieves comparable or superior sorting accuracy with reduced complexity and easier customization through channel geometry adjustments.
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
This system enables accurate and efficient sorting of objects by ensuring precise ejection based on measured properties, reducing occlusion risks and improving throughput by allowing for flexible channel lengths and shapes, and minimizing the ejection of unwanted objects.
Implementation Method 1
an object measurement unit for conducting an optical measurement associated with a property of the object via the first aperture
Data Source
AI summary
A method is disclosed for sorting a plurality of objects including an object that is one of a grain, a nut, a tree nut, or a bean. The plurality objects are conveyed along a guide plate having at least two channels between a first end and a second end of the corresponding channel. The channels have a first aperture provided at a first longitudinal position thereof and an additional aperture provided at a second longitudinal position on the guide plate located downstream of the first aperture. An optical measurement associated with a property of the object of the plurality of objects is conducted when the object passes the first aperture towards the second end with an object measurement unit. The object conveyed on the corresponding channel is ejected with an ejector unit when reaching the second longitudinal position based on the measured property of the object and a timing signal.