Automated DVD Sorting with Dual-Code Optical Verification
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Solution Overview
Problem
Conventional DVD rental services face inefficiencies due to extensive manual processing of returned and outgoing digital media, which hampers quick and reliable turn-around and can result in incorrect redistribution of DVDs.
Innovation Solution
An automated system using a camera on a sorting machine to scan codes on the DVD hub and sleeve, with additional checks for multiple discs or incorrect packaging, and a thickness sensor to verify the presence and correct positioning of a single disc, ensuring accurate sorting and redistribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual processing is used to inspect and sort returned DVDs, then flexibility and error correction are maintained, but processing time increases and productivity decreases
Solution Approach 1:
The patent replaces manual mechanical inspection with an automated optical scanning system. A camera scans barcodes on both the DVD hub and sleeve, and a computer automatically compares the codes to determine matches, eliminating the need for manual visual inspection while maintaining accuracy.
Solution Approach 2:
The system creates digital copies of the barcode information from the physical DVD and sleeve through optical scanning. The scanned barcode images are processed by a computer to verify matching, replacing manual verification with digital data comparison.
2Productivity
If automated scanning is used to speed up processing, then productivity increases, but the complexity of the detection and measurement system increases
Solution Approach 1:
The system divides the detection task into separate, simple components: a camera to scan the DVD barcode, a camera to scan the sleeve barcode, and a computer to compare the two codes. This segmentation makes the overall complex task manageable through simple individual steps.
Solution Approach 2:
The patent introduces a camera as an intermediary device between the physical barcodes and the computer. The camera converts the physical barcode information into digital signals that the computer can process, simplifying the interface between the physical world and the digital processing system.
3Reliability
If manual inspection is performed to verify DVD-sleeve matching, then reliability is maintained, but loss of time increases
Solution Approach 1:
The automated scanning system operates continuously without interruption. The camera scans barcodes as DVDs move through the sorting mechanism, and the computer continuously compares codes, eliminating the start-stop nature of manual inspection and maintaining constant productive action.
Solution Approach 2:
The system performs preliminary scanning of barcodes on both the DVD and sleeve before the actual sorting decision is made. This allows the computer to pre-verify matching and prepare the sorting action, reducing the time needed for the final verification step.
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 automation streamlines the processing of returned DVDs, reducing manual errors and ensuring rapid turn-around by accurately identifying and correcting mismatches, thereby enhancing customer satisfaction and operational efficiency.
Implementation Method 1
A camera on a sorting machine is used to scan a first code on a hub of the disc through a sleeve opening. The camera also scans a second code printed on the sleeve.
Implementation Method 2
a thickness sensor is used to determine whether the thickness of the mailed digital media package is too much or too little for a single disc
Data Source
AI summary
The present invention provides for automation of the process of ensuring that the contents of the return mailed digital media, comprising a disc enclosed in a sleeve, is correct for redistribution. A camera on a sorting machine is used to scan a first code on a hub of the disc through a sleeve opening. The camera also scans a second code printed on the sleeve. The sorter computer compares the first and second codes to determine whether the first and second codes correspond. If the first and second codes do not correspond, the sorter outsorts the mailed digital media so that the mismatch problem can be corrected. In a further embodiment, the system detects whether there are more or less than a single disk in the mail package. In the preferred embodiment, the mailed digital media is further composed of an envelope that receives and encloses the sleeve. The sorter scanner scans first code is further comprised of scanning the first code through an envelope opening, preferably the same envelope opening used for scanning of the first code.