Cullet Sorting via Non-Linear Spectral Analysis and Multi-Actuator Deflection
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Solution Overview
Problem
Current glass sorting technologies face limitations in distinguishing between different glass types and colors, particularly with shades of green, brown, or blue, and require multiple sorting stages, actuators, and high-energy x-ray sources, leading to inefficiencies and increased costs.
Innovation Solution
A system utilizing a combination of light emitting sources, cameras, radiation-emitting sources, and sensors to analyze the spectral characteristics of glass cullet, with actuators like fluid or electrostatic devices to direct the cullet into specific paths based on calculated non-linear functions, enabling multi-level sorting of glass types and colors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If red and green lamps are used for glass sorting, then the system can differentiate between some glass colors, but it cannot distinguish between shades of green, brown, or blue
Solution Approach 1:
The patent changes the spectral parameters of the light source from limited red and green wavelengths to a broad-spectrum white light source combined with multiple wavelength LEDs (red, green, blue, and ultraviolet). This parameter expansion enables the system to detect a wider range of glass colors and shades, resolving the contradiction between measurement precision and spectral adaptability.
2Device complexity
If a single actuator is used for binary sorting, then the system structure is simple, but multiple sorting stages are required which increase cost, energy, and time
Solution Approach 1:
The patent segments the single binary sorting function into multiple independent actuators (first actuator for binary sort, second actuator for multi-way sort). This segmentation allows the system to perform multiple sorting operations simultaneously in a single pass, eliminating the need for sequential multi-stage sorting and thereby improving productivity without significantly increasing overall system complexity.
Solution Approach 2:
The patent transitions from a one-dimensional binary sorting approach to a multi-dimensional sorting system by adding a second actuator that operates in a different dimensional space. This enables the system to sort glass into multiple paths simultaneously, effectively adding a new dimension to the sorting process and resolving the contradiction between device simplicity and sorting efficiency.
3Measurement precision
If x-ray fluorescence is used for material identification, then glass types can be distinguished, but the system requires high power and produces dangerous radiation
Solution Approach 1:
The patent replaces the expensive and hazardous x-ray fluorescence method with a combination of more affordable, safer light sources (white light and multiple wavelength LEDs) and optical sensors. This substitution maintains the ability to identify glass types through spectral analysis while eliminating the need for high-power radiation sources, thereby resolving the contradiction between measurement precision and safety.
Solution Approach 2:
The patent substitutes the x-ray fluorescence mechanism with an optical-based detection system using visible and ultraviolet light sources combined with photodetectors and spectrometers. This mechanism substitution achieves material identification through non-ionizing radiation, eliminating the harmful effects of x-rays while preserving the analytical capability to distinguish between different glass types.
4Ease of operation
If air driven jets are used to deflect cullet, then the system can sort glass, but small cullet less than 0.25 inches cannot be properly sorted due to delay
Solution Approach 1:
The patent replaces the traditional air-driven jet system with a hydraulic actuator system that uses liquid (water or other incompressible fluid) instead of gas. This substitution eliminates the compressibility delay inherent in air systems, providing immediate response to control signals and enabling effective deflection of small cullet particles less than 0.25 inches in size, thereby resolving the contradiction between operational ease and response speed.
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 effectively separates glass cullet into distinct groups by type and color, reducing the need for multiple sorting stages and high-energy sources, improving efficiency and reducing costs while accurately distinguishing between various glass types and colors.
Implementation Method 1
The cullet have different color characteristics which attenuate the light emitted from the light source in different amounts
Implementation Method 2
at least one radiation-emitting source for irradiating the glass cullet, causing the glass cullet to fluoresce and emit a spectrum of radiation
Data Source
AI summary
A system for sorting a mixed stream of colors and types of cullet into separate groups of cullet with similar color and type includes a source for transmitting light through a cullet, and a camera having a plurality of pixels for receiving light transmitted through the cullet or detecting the absence of light blocked by an opaque contaminant, the camera providing at least one value from the light received, wherein the cullet moves along a designated path based in part on the at least one value. The system further includes a radiation source for irradiating a cullet with selected spectral ranges of radiation, and a sensor for determining characteristics of one or more selected spectral ranges of fluorescent radiation emitted by the cullet, wherein the cullet moves along a designated path based in part on the characteristics of the one or more selected spectral ranges of fluorescent radiation. The camera and the sensor collect the received light at desired sampling intervals and a circuit converts the output of the camera and the sensor into digital representation values. The circuit calculates a non-linear function from the digital representation values. An electrostatic or fluid driving actuator directs the cullet along a deflected path based on a value of the non-linear function. A vibratory feeder provides the cullet onto a conveyer belt having an exit roller of a desired diameter.