Modular Object Sorting With Inclined Guide Channels
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Solution Overview
Problem
Existing object sorting systems are imprecise, require large space, and have limited capacity, particularly those using cameras or rotating drums, leading to inefficient sorting and high space requirements.
Innovation Solution
A system comprising a guide plate with inclined channels, an inlet manifold for distributing objects to sorting units, and an outlet manifold for collecting sorted objects, utilizing pneumatic ejector units and a modular design to enhance precision and compactness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If camera-based sorting systems are used to detect object properties, then measurement capability is improved, but device complexity and space requirements increase significantly
Solution Approach 1:
The patent replaces complex camera-based optical detection systems with a much simpler mechanical sensing approach. Objects are conveyed through channels with sensors that detect properties like reflectivity or presence using minimal components, eliminating the need for bulky cameras, wide-angle lenses, and complex image processing systems while maintaining effective sorting capability
Solution Approach 2:
Instead of using complex camera systems to capture and analyze object images, the patent employs simplified sensing mechanisms that directly detect object properties through the channel walls or at strategic points. This copying approach uses minimal optical or electromagnetic sensing elements rather than full imaging systems, dramatically reducing device complexity
2Measurement precision
If waterfall-style camera systems are used to capture entire object stream width, then measurement coverage is improved, but space requirements increase due to bulky equipment placement
Solution Approach 1:
The patent transitions from a horizontal waterfall-style layout requiring wide horizontal space to a vertical stacked arrangement where multiple sorting units are arranged one above another. Objects flow downward through inclined channels, allowing the system to cover the entire stream width using vertical stacking rather than horizontal expansion, dramatically reducing the footprint area
Solution Approach 2:
The sorting system is divided into multiple independent sorting units, each handling a portion of the object stream. These units are stacked vertically and can process objects in parallel as they flow downward, enabling comprehensive stream coverage through modular segmentation rather than requiring a single large horizontal camera system
3Measurement precision
If rotating drum systems with pockets are used for object sorting, then object characterization capability is improved, but device complexity and space requirements increase
Solution Approach 1:
The patent replaces the complex rotating drum mechanism with stationary inclined channels. Objects move through these channels under gravity rather than being lifted and carried by rotating pockets. Sensors positioned within the channels detect object properties during flow, eliminating the need for mechanical drum rotation while maintaining effective object characterization and sorting
Solution Approach 2:
The patent extracts the essential sorting function from the complex rotating drum system and implements it through simple inclined channels with integrated sensors. The drum's object-carrying pockets and rotation mechanism are completely removed, retaining only the core functionality of conveying objects past detection points for characterization and sorting
4Area of stationary object
If stacked sorting units are arranged vertically to reduce space, then space efficiency is improved, but device complexity increases due to manifold coordination
Solution Approach 1:
The patent merges the distribution and collection functions into integrated manifold structures that are inherently coordinated with the stacked sorting units. The inlet manifold distributes objects to multiple units, and the outlet manifold collects sorted objects, with both manifolds designed as unified components that automatically coordinate the stacked units, eliminating the need for complex external coordination systems
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 system achieves precise sorting with improved throughput and reduced space requirements by using inclined channels and modular design, allowing for efficient distribution and collection of sorted objects.
Implementation Method 1
a guide plate having at least one channel extending in a sorting plane inclined relative a horizontal reference plane for conveying objects from a first longitudinal position to a second longitudinal position downstream to the first longitudinal position, wherein the first longitudinal position is elevated relative the second longitudinal position
Data Source
AI summary
Described is an object sorting system and an object distribution and conveying arrangement for distributing and conveying a plurality of objects. The object sorting system includes a plurality of sorting units. The plurality of sorting units includes a sorting system that includes an object measurement unit for conducting measurement associated with at least one property of an object of the plurality of objects and at least one ejector unit arranged to eject the object conveyed based on the at least one measured property of the object.