Conveyor Object Identification With Counterweighted Diversion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for monitoring manufacturing consistency and accuracy of objects on conveyer mechanisms are inefficient and time-intensive, particularly when operating at high speeds, leading to potential production of defective products before errors are detected.
Innovation Solution
A system comprising a diverting bar with a counterweight and an object identifier, which includes an object collector, inspector, and selection arm, to automate the process of diverting, inspecting, and directing objects based on markings for quality control, reducing the risk of damage and enabling efficient sampling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual sampling methods are used to collect and identify objects on conveyer mechanisms, then the process is simple to implement, but it is time-intensive and inefficient
Solution Approach 1:
The patent replaces manual mechanical sampling with an automated optical identification system using imaging devices and image processing algorithms. The system captures images of objects on the conveyer, automatically identifies markings or defects, and determines whether objects should be diverted for further inspection, eliminating the need for manual collection and identification
Solution Approach 2:
The system enables self-service by allowing the conveyer system to automatically identify and flag objects requiring inspection without human intervention. The imaging devices and processing algorithms work autonomously to monitor objects as they pass through the manufacturing line, with the system self-determining which objects need to be diverted based on automated analysis
2Productivity
If high-speed manufacturing is used to increase production output, then productivity improves, but the risk of producing defective products before detection increases
Solution Approach 1:
The patent implements continuous monitoring of objects as they move through the manufacturing line at high speed. The imaging devices continuously capture images of objects on the conveyer, and the system continuously processes these images to identify defects or marking issues in real-time, ensuring uninterrupted quality surveillance throughout the manufacturing process
Solution Approach 2:
The system incorporates feedback mechanisms where the automated identification results are immediately used to control the diverting mechanism. When a defect or marking issue is detected, the system provides real-time feedback to divert the affected object for further inspection or rejection, creating a closed-loop quality control system that responds instantly to detected issues
3Productivity
If automated identification systems are implemented to improve sampling efficiency, then productivity increases, but device complexity increases
Solution Approach 1:
The patent employs a multi-functional integrated system where a single conveyer mechanism serves multiple purposes: transporting objects, positioning them for imaging, and facilitating diversion of identified objects. The imaging system is integrated with the conveyer control system, allowing one system to perform both transportation and quality inspection functions, reducing the need for separate dedicated components
Solution Approach 2:
The patent uses an image processing algorithm as an intermediary between the physical object and the control system. The algorithm processes raw images, identifies markings or defects, and translates this information into control signals for the diverting mechanism, serving as a mediator that bridges the gap between optical detection and mechanical action without requiring complex direct coupling
4Manufacturing precision
If diverting mechanisms are used to separate objects for inspection, then quality control accuracy improves, but the risk of object damage increases
Solution Approach 1:
The patent incorporates cushioning elements at the diverting mechanism to protect objects during the diversion process. Soft contact surfaces or damping materials are positioned at the point where objects are redirected, providing beforehand cushioning that absorbs impact forces and prevents damage to the objects being diverted for inspection
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
The system allows for cost-effective and efficient identification and sorting of objects on conveyer mechanisms, ensuring consistent product quality by reducing damage and enabling timely detection of defects.
Implementation Method 1
a counterweight configured to apply a biasing force against the one or more objects contacting the surface of the diverting bar
Data Source
AI summary
A system for identifying an object including a conveyer mechanism, a diverting bar, a counterweight, an object collector, an object inspector, and a selection arm. The diverting bar includes a body which may be positioned at least partially over the conveyer mechanism as to divert one or more objects of a plurality of objects traveling on the conveyer mechanism. The counterweight is coupled to the diverting bar and applies a biasing force against the one or more objects as to reduce the force applied to the plurality of objects. The object collector may be positioned adjacent the conveyer mechanism and is configured to accept an object from the conveyer mechanism and inspect the object for at least one marking. Once inspected, the selection arm is configured to deliver the object to a target position or back to the conveyer mechanism based on at least one marking.