Pellet Flow Channel Airflow Control for Multi-Angle Sorting
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Solution Overview
Problem
Existing polyethylene pellet sorting systems face challenges in capturing comprehensive all directional multi-angle images due to unpredictable pellet rolling during descent, leading to inaccurate defect identification.
Innovation Solution
A method and device that actively induce and control pellets to roll, rotate, or maintain stillness within a flow channel using controlled airflows, enabling comprehensive multi-angle imaging and precise sorting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple multimodal cameras are positioned on one side of the falling path to capture pellet images, then the system can attempt to identify defects, but it cannot capture all directional multi-angles' images of rolling pellets
Solution Approach 1:
The patent transitions from a single-side camera arrangement to a three-dimensional spatial configuration where cameras are positioned at multiple locations around the pellet flow channel. This dimensional expansion enables comprehensive multi-angle imaging coverage that was impossible with single-side positioning, directly resolving the information loss problem while maintaining measurement precision.
Solution Approach 2:
The imaging system is segmented into multiple camera units positioned at different spatial locations around the pellet flow channel. Each camera captures images from its specific viewpoint, and the combined data from all camera segments provides complete multi-angle coverage, solving the limitation of single-side camera positioning.
2Device complexity
If pellets fall in free-fall manner in the falling path, then the system structure can be simple, but it is unpredictable whether or when pellets will roll during descent
Solution Approach 1:
The patent introduces active dynamic control through airflow generation devices that can adjust air flow parameters in real-time. This transforms the static, unpredictable free-fall system into a dynamic system where pellet motion (including rolling behavior) can be controlled and predicted, while the modular airflow devices keep the overall structure complexity manageable.
Solution Approach 2:
The patent uses pneumatic airflow generation devices to control pellet motion within the flow channel. By introducing controlled air currents, the system achieves predictable pellet rolling and positioning without requiring complex mechanical structures, resolving the contradiction between structural simplicity and motion predictability.
3Loss of information
If controlled airflows are used to induce pellet rolling and rotation for multi-angle imaging, then comprehensive images can be captured, but energy consumption increases
Solution Approach 1:
The patent employs periodic or pulsed airflow patterns rather than continuous air flow to induce pellet rolling. By applying airflow in periodic bursts synchronized with the imaging process, the system achieves the necessary multi-angle image coverage while minimizing overall energy consumption compared to continuous airflow.
Solution Approach 2:
The system dynamically adjusts airflow parameters (velocity, duration, direction) based on the specific imaging requirements and pellet position. By optimizing these parameters in real-time, the system achieves effective multi-angle imaging with minimal energy expenditure, resolving the contradiction between information coverage and energy use.
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
Facilitates accurate identification and sorting of polyethylene pellets by capturing all directional images, improving defect detection and purity analysis.
Implementation Method 1
supplying a first airflow and a second airflow to the pellet flow channel, the first airflow jets from the first end of the pellet flow channel to the second end, causing the plurality of pellets to move from the first end to the second end of the pellet flow channel
Implementation Method 2
the second airflow jets from the second end of the pellet flow channel towards the first end, inducing and controlling the plurality of pellets by the first airflow and second airflow to make them roll, rotate, tumble, or maintain momentarily stillness as they pass through the pellet flow channel
Implementation Method 3
using an optical camera to comprehensively capture all directional multi-angles' images of the plurality of pellets from the pellet flow channel
Data Source
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AI summary
A pellet sorting method and device, and its pellet flow channel comprising: feeding a plurality of pellets (16) into the pellet flow channel (10) and providing a first airflow (35) and a second airflow (36) to the pellet flow channel (10). Controlling the presence, angle, direction, flow rate, and frequency of the first airflow (35) and the second airflow (36) thereby inducing and controlling the plurality of pellets (16) to undergo motion such as rolling, rotating, tumbling or maintaining momentarily stillness. This allows an optical camera (18) to comprehensively capture all directional multi-angles' images of the plurality of pellets (16) in the pellet flow channel (10), which are then sent to a digital image data processor for identification and analysis. If it is determined that all the plurality of pellets (16) meet predetermined conditions, all the plurality of pellets (16) direct to the first collection path (21). If one or more the plurality of pellets (16) are determined to not meet the predetermined conditions, the first airflow (35) is instantaneously air pneumatic ejected at high speed, directing all the plurality of pellets (16) toward the second collection path (23).