Gapping Scale Conveyor Control for Precise Product Classification
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Solution Overview
Problem
Existing product processing systems lack automation and software for efficient separating, weighing, and classifying of products, particularly meat products, with limited human intervention.
Innovation Solution
A gapping scale conveyor system comprising a gapping conveyor, a multi-zone scale conveyor, and a control system that dynamically adjusts the gap between products using sensors and imaging devices to achieve precise spacing and weighing, and a classification device with a sensor enclosure and imaging device for product classification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If existing separating, weighing, and classifying equipment is used, then product processing can be performed, but automation and software for efficient processing with limited human input are lacking
Solution Approach 1:
The patent replaces manual mechanical operations with an automated control system that uses sensors (optical, weight, thermal) to detect product characteristics and automatically adjusts conveyor speed, gap settings, and classification decisions, eliminating the need for human operators to manually separate, weigh, and classify products
Solution Approach 2:
The system enables products to be automatically processed through self-service mechanisms where sensors detect product properties and the control system autonomously makes classification and sorting decisions without human intervention, with the equipment serving itself to maintain optimal operating parameters
2Manufacturing precision
If products are moved through the conveyor system, then processing continues, but maintaining consistent gap between products is difficult without automated control
Solution Approach 1:
The patent employs feedback mechanisms where optical sensors continuously monitor the gap between products on the conveyor belt and provide real-time data to the control system, which then automatically adjusts conveyor speed or actuates gap control mechanisms to maintain consistent spacing, creating a closed-loop control system that self-corrects deviations
Solution Approach 2:
The system uses dynamic control where conveyor speeds and gap settings are continuously adjusted in real-time based on product characteristics and positioning, rather than using fixed static parameters, allowing the system to adapt to varying product sizes and maintain optimal gap consistency throughout processing
3Measurement precision
If multiple sensors and imaging devices are added for accurate classification, then measurement precision improves, but device complexity increases
Solution Approach 1:
The patent implements multi-functional sensors that perform multiple measurement tasks simultaneously - for example, optical sensors that detect both product color and shape characteristics, or weight sensors that measure both mass and dimensional properties, reducing the total number of separate sensing devices needed while maintaining high classification accuracy
Solution Approach 2:
The system combines multiple sensing modalities (optical, weight, thermal) into an integrated sensor array that works in unison under coordinated control, merging data from various sensors to create a comprehensive product profile that improves classification accuracy while reducing the complexity of individual sensor systems through shared processing infrastructure
Data Source
AI summary
Various gapping conveyors and classification conveyors, including combination gapping and classification conveyors along with separate gapping conveyors and classification devices. In some embodiments, the gapping scale conveyor system includes both a gapping conveyor and a multi-zone scale conveyor in the same device and further includes a computing device for controlling the two conveyors. In other embodiments, a gapping conveyor having three conveyor belts is provided, and separately a classification device is provided having a conveyor with a scale and a hood with various sensors therein, including an imaging device.