Movable Fill-Level Sensing for Textile Sorting Bins
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Solution Overview
Problem
Existing textile sorting systems face inefficiencies due to uneven filling of sorting bins, leading to overfilled or underutilized bins, and require complex sensor networks that increase installation and maintenance costs, reducing reliability and scalability.
Innovation Solution
A method and device using movable sensors to determine the filling level of sorting bins, eliminating the need for multiple fixed sensors and cabling, and optimizing bin emptying based on threshold values for efficient sorting and space utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If weight measurement is used to determine bin fullness, then automated emptying is achieved, but system complexity increases due to complex sensor networks and wiring
Solution Approach 1:
A single sensor performs multiple functions: it measures both the height of textile items and the weight of sorting bins by detecting changes in its operational characteristics (oscillation frequency or resonance frequency). This eliminates the need for separate height sensors and weight sensors at each bin location, significantly reducing system complexity while maintaining automated emptying capability.
Solution Approach 2:
The sensor system can operate in multiple modes: it can measure height when items are being sorted, and measure weight when bins are stationary. This multi-functional approach allows one sensor to replace what would traditionally require multiple specialized sensors, reducing wiring and installation complexity.
2Measurement precision
If individual sensors are installed in each sorting bin, then accurate fill level measurement is achieved, but installation and maintenance costs increase significantly
Solution Approach 1:
Instead of installing separate height sensors and weight sensors in each bin, a single multi-functional sensor is positioned to serve multiple bins sequentially. This sensor can measure both height and weight parameters for different bins at different times, eliminating the need for multiple sensors per bin and significantly reducing installation and maintenance costs.
Solution Approach 2:
The sensor system is dynamic rather than static - it can be moved between different bin locations and configured to measure different parameters as needed. This dynamic deployment allows one sensor to perform the work of many fixed sensors, reducing overall system cost while maintaining measurement precision.
3Measurement precision
If multiple sensors and cabling are used for each sorting bin, then monitoring capability is improved, but system reliability decreases due to more potential failure points
Solution Approach 1:
By using a single multi-functional sensor that can measure both height and weight, the number of potential failure points is dramatically reduced. Instead of having multiple sensors and extensive cabling that could fail, the system uses one robust sensor with fewer connection points, thereby improving overall system reliability while maintaining comprehensive monitoring capability.
4Extent of automation
If weight-based estimation is used to determine fill level, then automated control is achieved, but measurement accuracy decreases because mass does not directly correspond to volume
Solution Approach 1:
The single sensor system provides both height measurement and weight measurement capabilities. By combining these two measurements, the system can calculate fill level with high accuracy - using height to determine volume occupied and weight to determine mass, thereby deriving density and improving overall fill level estimation accuracy compared to weight-only methods.
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 efficient sorting by automatically emptying only the fullest bins, optimizing workspace, reducing manual intervention, and minimizing energy consumption while ensuring accurate and reliable fill level measurements.
Implementation Method 1
determining a filling level of the sorting bins by means of one or more sensors that move above the sorting bins
Data Source
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AI summary
The present invention relates to a method for sorting textile, the method comprising distributing a quantity of textile items among two or more sorting bins, wherein each sorting bin receives textile items belonging to a same textile category, wherein the sorting bins are arranged in series; determining a fill level of each sorting bin by means of one or more sensors that are movably arranged above the sorting bins and move over the sorting bins; and emptying the sorting bins based on the fill level. The invention also relates to a device which is suitable for carrying out said method.