Infrared Selector Machine for Bulk Sorting
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Solution Overview
Problem
Existing selector machines for separating solid elements in bulk products are costly due to hyperspectral video cameras, have low image acquisition frequency, and require heavy computational processing, leading to inefficiencies and inaccuracies in distinguishing elements with similar visible colors based on chemical-physical properties.
Innovation Solution
A selector machine employing multiple IR sources emitting electromagnetic radiations in distinct spectral bands, a processing module for false color synthesis, and a bandpass filter to differentiate elements based on infrared absorption, reducing the need for hyperspectral cameras and enhancing image acquisition frequency and resolution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a hyperspectral video camera is used to detect elements with similar visible colors, then measurement precision is improved, but device complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent segments the electromagnetic spectrum detection into multiple discrete infrared wavelength bands (e.g., 900nm, 1300nm, 1550nm) using separate LED sources and corresponding optical filters, rather than using a single hyperspectral camera. This segmentation approach maintains detection precision while reducing device complexity by using simple, inexpensive components for each wavelength band.
Solution Approach 2:
The patent changes the detection parameter from visible light spectrum to multiple specific infrared wavelength bands. By detecting elements' absorption characteristics at different infrared wavelengths, the system achieves precise differentiation of materials with similar visible colors, while using parameter changes (wavelength selection) rather than complex hyperspectral imaging.
2Measurement precision
If a hyperspectral video camera is used for multi-spectral detection, then measurement precision is improved, but productivity decreases due to low image acquisition frequency
Solution Approach 1:
The patent uses periodic action by sequentially activating multiple LED sources at different infrared wavelengths in rapid succession. Each LED emits at its specific wavelength in alternating cycles, and the image sensor captures reflected light from each wavelength band sequentially. This periodic illumination at multiple wavelengths achieves precise spectral detection while maintaining high overall frame rate, thus improving productivity compared to true hyperspectral cameras.
3Measurement precision
If a hyperspectral video camera is used for detailed spectral analysis, then measurement precision is improved, but loss of time increases due to heavy computational processing requirements
Solution Approach 1:
The patent extracts only the essential spectral information by detecting reflected light intensity at a few key infrared wavelength bands rather than capturing the entire spectrum. This extraction approach focuses on the most discriminative wavelengths for material identification, significantly reducing data volume and computational processing time while maintaining sufficient detection precision for industrial sorting applications.
Solution Approach 2:
The patent replaces the expensive, computationally intensive hyperspectral camera with multiple inexpensive LED sources and simple optical filters. Each LED-filter combination acts as a simple, low-cost detection channel that requires minimal processing. This substitution of cheap, simple components for expensive complex ones reduces both manufacturing cost and processing time requirements.
4Ease of manufacture
If multiple IR sources with distinct spectral bands are used, then manufacturing cost is reduced, but measurement precision may deteriorate without proper wavelength selection
Solution Approach 1:
The patent applies local quality by selecting specific infrared wavelength bands (900nm, 1300nm, 1550nm) that correspond to characteristic absorption features of different materials. Each wavelength band is optimized for detecting specific material properties, ensuring that the simple LED-based system achieves measurement precision comparable to or exceeding hyperspectral cameras for the target application of sorting materials with similar visible colors.
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 solution provides a cost-effective, high-resolution image acquisition system with increased processing efficiency, enabling precise separation of elements with similar visible colors by leveraging infrared differences, thus improving operational reliability and reducing manufacturing costs.
Implementation Method 1
the emitter device (4) comprises at least three IR sources (8), each of which arranged for emitting electromagnetic radiations (40) in a corresponding spectral band (80) in the infrared spectrum
Implementation Method 2
an optical sensor (5), which is directed towards the advancement path (A) and is arranged for receiving reflected radiations RF coming from the bulk product irradiated by the electromagnetic radiations (40)
Implementation Method 3
elements having the same color in the visible spectrum generally have chemical-physical characteristics that determine a different absorption spectrum at the infrared wavelengths
Data Source
AI summary
Selector machine comprising an optical detection system provided with an emitter device and with an optical sensor adapted to detect a product to be selected. The emitter device comprises three IR sources, each of which emits electromagnetic radiations in a corresponding spectral band in the infrared spectrum. An electronic control unit alternately turns on the IR sources in corresponding separate time intervals, and the optical sensor detects, in each time interval, corresponding reflected radiations coming from the product. In addition, the electronic control unit comprises a processing module, which is provided with three chromatic channels of a RGB color space in order to associate the measurement signals corresponding to each IR source with a corresponding chromatic channel so as to compose a false color synthesis image of the product.