Automated Circuit Board Sorting by Layout-Based Metal Classification
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Solution Overview
Problem
Current manual sorting of circuit boards for recycling is inefficient and prone to human error, as workers struggle to accurately recognize and sort boards based on design, size, weight, composition, and precious metal content, leading to inefficiencies and high costs in the recycling process.
Innovation Solution
An automated system that scans circuit boards, compares their layout designs with a database of known designs, and assigns precious metal designations based on matches, sorting boards into groups for efficient processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual sorting is used, then labor intensity is low, but sorting accuracy and efficiency are insufficient
Solution Approach 1:
The patent replaces the manual mechanical sorting system with an automated optical recognition system. Cameras capture images of circuit boards, image processing algorithms identify board types and precious metal content, and robotic arms automatically sort boards into designated containers. This substitution eliminates human labor while significantly improving sorting efficiency and accuracy.
Solution Approach 2:
The patent creates a digital copy of each circuit board through image capture and stores it in a database. The system then compares images of incoming boards against the database to automatically identify board types and precious metal content, enabling rapid sorting without manual inspection of each board's physical characteristics.
2Measurement precision
If manual sorting is used, then equipment cost is low, but human error increases and accuracy decreases
Solution Approach 1:
The patent replaces human visual inspection and manual sorting with an automated optical recognition system. High-resolution cameras capture detailed images of circuit boards, and image processing algorithms analyze the images to identify board types, layouts, and precious metal content with high accuracy, eliminating human error entirely.
Solution Approach 2:
The patent implements a feedback mechanism where the image processing system continuously compares captured board images against a database of known board types and precious metal compositions. The system provides real-time feedback on board identification accuracy and can correct misclassifications, ensuring high sorting precision.
3Loss of time
If manual sorting is used, then implementation is simple, but processing time increases significantly
Solution Approach 1:
The patent implements continuous automated sorting where circuit boards are processed in a steady stream without interruption. The robotic arms continuously capture images, analyze boards, and sort them into containers as they move along the conveyor belt, eliminating the stop-start nature of manual sorting and significantly reducing processing time.
Solution Approach 2:
The patent performs preliminary actions by pre-processing and storing images of known circuit board types and their precious metal contents in a database before actual sorting occurs. This allows the system to rapidly compare and identify incoming boards without manual reference materials, speeding up the sorting process.
4Productivity
If manual sorting is used, then operational simplicity is maintained, but labor costs and inefficiency increase
Solution Approach 1:
The patent replaces manual labor with an automated robotic system that performs all sorting operations. The robotic arms, guided by optical recognition and image processing, can process thousands of circuit boards per hour, dramatically increasing throughput while eliminating the need for large workforces.
Solution Approach 2:
The patent designs a universal automated sorting system that can handle multiple types of circuit boards with different layouts, sizes, and precious metal contents using the same hardware infrastructure. The image processing algorithms and robotic arms are configured to accommodate various board types, making the system highly versatile and efficient.
Data Source
AI summary
An automated method for sorting circuit boards for recycling is described. The method includes scanning a layout design for a circuit board and comparing the scanned layout design with a database of circuit board layout designs. Each of the layout designs being associated with a respective precious metal content value. A match between the scanned layout design and one of the circuit board layout designs in the database is identified. The method then assigns a precious metal designation to the scanned circuit board based on the identified match. The precious metal designation corresponds to the precious metal content value associated with the matched circuit board layout from the database. The method also includes sorting the scanned circuit board into a group associated with the assigned precious metal designation.