Optical Sorting System Monolayer Feeding and Air Pulse Discharge
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Solution Overview
Problem
Existing optical sorting systems for granulate particles face issues with uncontrolled feeding, inaccurate discharge, and inefficiencies in sorting speed and space utilization, leading to suboptimal detection and separation of particles.
Innovation Solution
The system employs a dosing device for precise application of granulate particles onto a conveyor belt, an optical sensor for real-time detection, and a discharge device using air pulses to deflect particles into specific trajectories based on quality criteria, with pretreatment steps to remove contaminants and ensure accurate sorting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If granulate particles are fed onto the conveyor belt via a dosing chute using gravity, then the particles can be transferred to the conveyor belt, but an uncontrolled amount of particles is fed resulting in no guaranteed monolayer application
Solution Approach 1:
The patent applies preliminary action by pre-forming particles into particle tablets with binding agent before feeding them onto the conveyor belt. This pre-processing ensures that particles are applied in controlled, discrete units that maintain monolayer formation, eliminating the uncontrolled feeding issue of conventional dosing chutes.
2Productivity
If discharge devices using air pulses or scoop devices are employed, then particles can be discharged from the conveyor belt, but the discharge is inaccurate and does not allow for precise discharge of deviating particles
Solution Approach 1:
The patent segments the discharge function into multiple independently controllable air nozzles positioned at different locations. Each nozzle can be activated selectively based on the detected position and type of defect, enabling precise discharge of only the deviating particles while maintaining high productivity through parallel processing capability.
Solution Approach 2:
The system implements feedback by using optical sensors to detect deviating particles in real-time and immediately triggering the corresponding air nozzle to discharge the defective particle. This closed-loop control ensures high discharge accuracy while maintaining rapid processing speed.
3Productivity
If conventional optical sorting systems are used, then particles can be sorted into fractions, but the required installation space is large and sorting speed is limited
Solution Approach 1:
The patent merges multiple functions into a compact integrated system: the conveyor belt serves both as transport and detection surface, air nozzles are positioned directly above the belt for immediate particle discharge, and the control system integrates sensing, processing, and actuation. This functional integration significantly reduces installation space while maintaining high sorting speed.
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
This approach enables reliable detection and precise discharge of granulate particles, reduces installation space, and increases sorting speed, allowing for efficient separation of particles into distinct fractions while minimizing contamination and particle scattering.
Implementation Method 1
the optical sensor device generates optical images of the granulate particles in the region of the discharge end
Implementation Method 2
the granulate particles are deflected by the discharge device by means of at least one air pulse
Implementation Method 3
accelerated to a defined speed by the conveyor belt
Implementation Method 4
transferred into a free flight path... with an idealized, theoretical parabolic trajectory
Data Source
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AI summary
The invention relates to an optical sorting system for sorting granule particles into at least a first and second granule fraction, comprising: - a dosing device; - a conveyor belt; - an optical sensor device; - a discharge device; - a control device; and - at least a first and second granule fraction outlet.