Optical Sorter Ejector Control for Yield–Quality Balancing
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Solution Overview
Problem
Existing optical sorters require specialized maintenance engineers to adjust ejector nozzle settings for yield and quality, which is time-consuming and difficult for ordinary users.
Innovation Solution
An optical sorter with multiple ejector nozzles and sorting strength levels, allowing users to easily set operation parameters through a console screen, including ejection period, overlap value, and fault area identification, enabling automatic setting of parameters for different yield and quality requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If compressed air hits on a defective article for a long period of time and in a wide range, then the defective article can be reliably removed, but good articles may be involved in compressed air and removed together resulting in reduced yield
Solution Approach 1:
The ejector nozzle operation is made dynamic by allowing different operation modes (first operation mode for high yield, second operation mode for high quality) with different compressed air ejection parameters. The system can switch between these modes based on the desired outcome, making the ejection process adaptable rather than static.
Solution Approach 2:
The patent changes the parameters of compressed air ejection (ejection period, ejection range, timing) to resolve the contradiction. By adjusting these parameters between two operation modes, the system can achieve either high yield or high quality sorting depending on the specific needs.
2Reliability
If individual ejector nozzle operation parameters are set for high-quality sorting, then defective articles can be reliably removed, but specialized maintenance engineers need to take time to make settings through trial and error
Solution Approach 1:
The system performs preliminary action by pre-configuring two complete operation modes (first operation mode and second operation mode) with optimized parameters. This eliminates the need for trial-and-error adjustments during actual operation, as the appropriate mode is already prepared and can be selected directly.
Solution Approach 2:
The control unit automatically manages the switching between operation modes based on simple input from the setting unit. This self-service mechanism eliminates the need for specialized maintenance engineers to manually adjust individual parameters, making the system easy to operate for ordinary users.
3Ease of operation
If multiple operation parameters are set for different sorting strengths, then users can easily select desired yield and quality levels, but the device complexity increases
Solution Approach 1:
The control unit is designed with multi-functionality to manage both the first and second operation modes, as well as handle switching between them. This universal control mechanism simplifies the user interface while managing the complexity internally, allowing ordinary users to easily select operation modes without understanding the underlying complex parameters.
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
Users can easily adjust the sorter to achieve desired yield and quality without trial and error, improving efficiency and reducing the time required for setting adjustments.
Implementation Method 1
an ejector controller that includes multiple ejector nozzles and is configured to sort out the granular objects into the defective article and the good article by ejecting compressed air to the defective article from the ejector nozzles
Data Source
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AI summary
An optical sorter including: an inspection part that is configured to perform optical inspection on granular objects transferred by transfer means; a judgment part that is configured to judge whether each granular object is a good article or a defective article based on the optical inspection performed by the inspection part; an ejector controller that includes multiple ejector nozzles and is configured to sort out the granular objects into the defective article and the good article by ejecting compressed air to the defective article from the ejector nozzles; and a sorting strength setting part that is capable of setting a sorting strength in the ejector controller, wherein the sorting strength is constituted of multiple sorting strength levels, and the sorting strength setting part is capable of presetting, for each of the sorting strength levels, multiple kinds of operation setting parameters that control an operation of the ejector nozzles.