Optical Sorting Apparatus with Graphical User Interface for Defect Ejection
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Solution Overview
Problem
Optical sorting machines face challenges in optimizing the setup to effectively remove defects from bulk foodstuffs while minimizing the removal of good products, due to overlapping detection criteria and density issues, leading to uncertainty in adjusting sorting parameters and ejector blast areas.
Innovation Solution
The implementation of a graphical user interface coupled with a pattern recognition system that displays back-projected defect data and allows operators to adjust parameters, featuring a feed system with ejectors and a camera for image processing, enabling visualization of ejector areas and defect identification, and providing diagnostic tools like the defect viewer, Rogues' Gallery, and defect browser for fine-tuning the sorting process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the sensitivity of the sorting criterion is increased to detect more defects, then more defects are removed, but the proportion of good product that is incorrectly removed increases
Solution Approach 1:
The patent segments the sorting process by implementing multiple independent sorting criteria that can be individually adjusted and optimized. Each criterion targets specific defect types with tailored parameters, allowing the system to selectively remove defects while preserving good product. The graphical user interface displays defect detection results organized by different criteria, enabling operators to fine-tune each criterion's sensitivity independently.
Solution Approach 2:
The system allows dynamic adjustment of sorting criterion parameters through the graphical user interface. Operators can modify sensitivity thresholds, detection parameters, and criterion weights to optimize the balance between defect removal and good product preservation. The back-projection feature visually demonstrates how parameter changes affect defect detection and ejection decisions, enabling precise parameter optimization.
2Reliability
If the area of intersection of gas blast with product stream is extended to ensure defective article rejection, then defective articles are reliably removed, but acceptable articles are removed with the defective article
Solution Approach 1:
The patent applies local quality by enabling selective activation of individual ejectors or groups of ejectors based on the specific location and type of defect detected. Rather than extending the gas blast area uniformly across the entire product stream, the system targets only the specific regions where defects are located. The graphical user interface displays which ejectors will be activated and their specific coverage areas, allowing operators to optimize the blast area for each defect type and location.
Solution Approach 2:
The system performs preliminary identification and targeting of defects before activating the gas blast. The imaging system captures product stream images, the pattern recognition system identifies defect locations, and the graphical user interface pre-displays the planned ejection areas and activated ejectors. This preliminary action allows operators to verify that only the necessary ejectors with appropriate coverage areas are activated, minimizing collateral damage to acceptable articles.
3Reliability
If multiple ejectors are fired simultaneously or the duration of gas blast is extended to account for position and velocity uncertainties, then defective article rejection is improved, but the area of intersection with product stream increases causing more good product removal
Solution Approach 1:
The system dynamically adjusts ejector activation and gas blast duration based on real-time defect detection and product stream conditions. Rather than using fixed, extended blast areas to account for uncertainties, the system calculates the optimal ejector combination and blast timing for each detected defect. The graphical user interface displays the dynamic planning of ejection events, showing which ejectors are activated and for what duration based on the specific defect location, size, and product velocity.
Solution Approach 2:
The system incorporates feedback through the graphical user interface that displays the planned ejection areas and activated ejectors before actual operation. This feedback loop allows operators to verify that the dynamic ejector activation and gas blast duration are appropriate for the detected defects, and to make adjustments if the planned area of intersection appears excessive. The system continuously monitors and adjusts based on actual defect detection results.
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 solution facilitates better targeting of defective articles, reduces the removal of good products, and provides operators with clear guidance on adjusting parameters to optimize throughput and quality, enabling precise control over the sorting process.
Implementation Method 1
Optical sorting machines identify defects in the product being sorted by using known techniques for continuously creating images of product in the stream at an imaging zone
Implementation Method 2
a stream of particles to be sorted is delivered in free flight to a sorting zone where articles to be removed are rejected by blasts of gas, normally air, from ejectors disposed adjacent the flight path
Data Source
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AI summary
Sorting apparatus comprises a feed system for delivering a stream of articles in free flight to a sorting zone. Ejectors at the sorting zone are selectively activated to eject articles from the stream. A camera is disposed at an imaging zone upstream of the sorting zone to generate image data to be processed by a computer to identify articles to be ejected at the sorting zone according to one or more sorting criteria. The computer instructs the ejectors on the basis of the processed data. The computer is also coupled to a graphical user interface to display an image of the product stream at the imaging zone, and show the areas of intersection with the product stream of activated ejectors. The ejectors are normally operable to discharge a fluid such as a gas or air, in pulses, and the areas of intersection with the product stream are those directly intersected by the ejector fluid. Provision can be made for adjusting ejection parameters to move the boundaries of these areas of intersection.