Helical Drive Fruit Singulation for Field Sorting
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Solution Overview
Problem
Current machine vision systems for fruit sorting are fragile, complex, and too bulky to be suitable for the field environment, and there is a need for a mobile harvest-point system that can quickly and efficiently separate defective fruit from fresh produce during the harvesting process.
Innovation Solution
A modular machine vision system using helical drives to singulate and rotate apples into an imaging chamber for image evaluation, followed by a rotary sorter that places the apples into designated bins based on quality grade, which is compact, durable, and functional in the harvest environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional machine vision systems are used for fruit sorting, then sorting accuracy and quality evaluation are improved, but system complexity, bulkiness, and cost increase making them unsuitable for field environment
Solution Approach 1:
The system is divided into separate functional modules: helical singulating mechanism, imaging chamber with lighting, processor unit, and rotary sorter with bins. Each module performs a specific function, allowing the overall system to be more manageable and adaptable for field deployment while maintaining sorting accuracy
Solution Approach 2:
The system employs dynamic components including the rotating helical drives for singulation, the rotary sorter that rotates to deposit fruit into different bins, and movable imaging chambers. These dynamic elements enable continuous operation and adaptation to different sorting requirements without increasing permanent system bulk
2Productivity
If machine vision systems are deployed at harvest point, then cost savings from reduced storage and early defect removal are achieved, but system portability and durability for field conditions become critical challenges
Solution Approach 1:
The system parameters are optimized for field conditions: the imaging chamber provides controlled lighting conditions for accurate defect detection, the helical drives are designed with appropriate rotational speeds for gentle fruit handling, and the rotary sorter adjusts its rotation and bin positioning to ensure reliable fruit deposition. These parameter optimizations maintain system reliability while enabling early defect removal at harvest point
3Productivity
If continuous rotation and conveyance of fruit is implemented, then sorting speed and efficiency are improved, but mechanical stress on fruit and system complexity increase
Solution Approach 1:
The helical drives act as an intermediary mechanism between the conveyor and the sorting bins. They gently rotate and convey fruit through the imaging chamber without direct mechanical contact that would cause stress. The rotary sorter serves as another intermediary, using controlled rotation and gravity-assisted deposition to place fruit into bins with minimal mechanical impact, thereby maintaining sorting speed while protecting fruit integrity
Data Source
AI summary
As fruit (preferably apples) are harvested, the fruit is placed on a conveyor that conveys the fruit to a fruit singulating section. In the singulating section, the fruit is directed into slots in a lane formed by two cooperating helical drives. The helical drives rotate the fruit and convey the fruit into an imaging chamber where a camera acquires an image of the fruit. The fruit image is evaluated by a processor in communication with the camera. The fruit is then directed into a rotary sorter which sorts the fruit based on the image evaluation by the processor.