Color Sorter Illumination Device with Linear LED Arrays
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Solution Overview
Problem
Conventional color sorters require multiple illumination means in the optical detection part, leading to a large size and high power consumption, while also facing issues with unstable luminance and increased maintenance due to the complexity of light sources.
Innovation Solution
A compact illumination device for color sorters is designed with a longitudinal chassis for heat radiation, featuring linearly aligned LED elements on a triangular roof-shaped substrate, integrating two light sources - one for visible light and one for near-infrared light - to illuminate the items-to-be-sorted and the background, respectively, with an illuminance sensor and temperature sensor for constant light control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If multiple illumination means are installed in the optical detection part, then the illumination coverage is sufficient, but the device size increases and power consumption increases
Solution Approach 1:
The patent combines two separate illumination means into a single integrated illumination device. The first illumination means (for items-to-be-sorted) and the second illumination means (for background) are merged into one compact device with multiple LED arrays arranged to provide both illumination functions simultaneously, thereby reducing the overall device size while maintaining sufficient illumination coverage.
Solution Approach 2:
The integrated illumination device performs multiple functions: it illuminates both the items-to-be-sorted and the background using different LED arrays within the same device. This multi-functional design eliminates the need for separate illumination devices, reducing the number of components and overall device size while maintaining adequate illumination for both targets.
2Illumination intensity
If multiple illumination means are installed in the optical detection part, then the illumination coverage is sufficient, but the power consumption increases
Solution Approach 1:
By merging multiple illumination means into a single integrated device with shared control electronics and power supply, the patent reduces redundant power consumption. The integrated design allows for more efficient power distribution and enables independent control of different LED arrays, optimizing energy usage while maintaining sufficient illumination coverage.
Solution Approach 2:
The patent uses different types of LEDs (visible light LEDs and near-infrared LEDs) with different operational parameters to illuminate different targets. This allows for optimized power consumption by selecting LEDs with appropriate wavelengths and intensities for each specific illumination task, rather than using multiple identical high-power illumination sources.
3Illumination intensity
If conventional light sources are used, then the illumination is sufficient, but the luminance stability deteriorates and maintenance frequency increases
Solution Approach 1:
The patent incorporates illuminance sensors that detect the actual illumination levels and provide feedback to the control unit. The control unit adjusts the LED drive currents based on this feedback to maintain constant luminance output, compensating for LED aging and environmental variations, thereby ensuring stable illumination over time.
Solution Approach 2:
The illumination device includes self-diagnostic and self-adjustment capabilities through the feedback control system. The illuminance sensors continuously monitor the illumination output and automatically adjust the LED operation to maintain optimal performance, reducing the need for manual intervention and maintenance while ensuring consistent luminance stability.
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 configuration reduces the number of light sources, enhances heat dissipation, maintains stable luminance, and extends the device's lifespan by reducing power consumption and minimizing maintenance needs, resulting in a more efficient and cost-effective illumination solution.
Implementation Method 1
an LED substrate (3) placed on the chassis (2), and a light source (5) in which many LED elements (4) are linearly aligned in a longitudinal direction on the LED substrate (3)
Implementation Method 2
a longitudinal chassis (2) for heat radiation
Data Source
AI summary
An illumination device for a color sorter includes an LED substrate placed on a longitudinal chassis for heat radiation and a light source in which many LED elements are linearly aligned in the longitudinal direction on the LED substrate, and the light source is an integration of at least two light sources provided together, one of the light sources illuminating a side on which items-to-be-sorted flow down and the other one of the light sources illuminating a side of a background arranged to face a camera.