LED Sorting Tray Segmentation for Motion Time Reduction
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Solution Overview
Problem
Conventional LED sorting systems are inefficient due to uneven bin utilization and downtime caused by preset counter limits, leading to reduced sorting speed and throughput.
Innovation Solution
A sorting apparatus with a high-speed bin tray for frequently used LEDs and a normal bin tray for less frequently used LEDs, where the high-speed tray has fewer receptacles and is positioned closer to the output tube, allowing for reduced motion distance and time, and enabling continuous sorting operations by transferring full high-speed bins to normal bins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If bins are arranged in a matrix form with over a hundred bins for collecting LEDs, then the sorting system can handle diverse LED characteristics, but the motion distance and time for the output tube to move between bins increases substantially
Solution Approach 1:
The patent divides the bin array into multiple sub-arrays or groups, allowing the output tube to serve fewer bins in each group more efficiently. This segmentation reduces the motion distance within each sub-array while maintaining the overall capability to handle diverse LED characteristics across all groups.
Solution Approach 2:
The patent employs dynamic bin assignment where bins can be reassigned to different characteristic categories based on real-time sorting needs. This dynamic reconfiguration allows frequently accessed bins to be positioned optimally, reducing motion time while maintaining adaptability to various LED characteristics.
2Measurement precision
If each bin is preset to collect a certain number of LEDs with preset counter limits, then the sorting system can track bin capacity, but the sorting operation must be set to idle when bins are full, reducing sorting speed and throughput
Solution Approach 1:
The patent implements continuous sorting operation by eliminating idle periods. When bins reach their capacity, the system automatically redirects the output tube to alternative bins or triggers real-time bin replacement, ensuring the sorting process continues without interruption and maintaining high throughput.
Solution Approach 2:
The sorting system incorporates automatic bin monitoring and replacement mechanisms that operate without halting the sorting process. The system self-manages bin capacity tracking and replacement, allowing continuous operation while maintaining precise measurement of bin contents through sensors and counters.
3Adaptability or versatility
If the output tube moves between bins that are far apart in the matrix arrangement, then all bins can be accessed, but the sorting speed decreases due to substantial motion time
Solution Approach 1:
The patent creates localized sorting zones where frequently accessed bins are grouped together in proximity to the output tube. Each zone is optimized for specific LED characteristic ranges, allowing rapid sorting of common types while less frequently accessed bins are positioned in peripheral locations, maintaining overall system versatility.
Data Source
AI summary
A sorting system is provided for electronic components such as LED devices which includes a testing station for testing and determining a characteristic of each electronic component. A first tray has a plurality of receptacles for receiving tested electronic components and a second tray has more receptacles than the first tray for receiving tested electronic components. Electronic components comprising tested characteristics that occur with greater frequency are loaded into the receptacles of the first tray and electronic components comprising tested characteristics that occur with lower frequency are loaded into the receptacles of the second tray.