Pellet Inspection System with Dual-Surface Vision and Vibration Transfer
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Solution Overview
Problem
Existing pellet sorting technologies face limitations in accurately detecting defects such as different colors, foreign substances, and abnormal shapes in pellets due to reliance on shape and size sorting methods, which are inefficient and fail to inspect both surfaces of hexahedral pellets, leading to low precision and high defect detection rates.
Innovation Solution
A system that includes a pellet supply part, transfer parts, vision inspection parts, and dispensing parts to photograph and inspect both surfaces of pellets in motion, using vibration and suction nozzles to separate defective pellets, and a sample inspector to manufacture and inspect molded product samples for defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If screen mesh sorting is used to sort pellets by shape and size, then the sorting process is simple, but the sorting precision deteriorates and cannot detect defects such as different colors, foreign substances, abnormal shapes, and dark spots
Solution Approach 1:
The patent replaces the mechanical screen mesh sorting system with an optical inspection system using cameras and image processing algorithms. The system captures images of pellets during transfer and uses AI-based image recognition to detect defects such as different colors, foreign substances, abnormal shapes, and dark spots, achieving high precision without complex mechanical sorting structures
Solution Approach 2:
The patent introduces an image processing system as an intermediary between the pellet transfer mechanism and the sorting action. Cameras capture pellet images, image processing algorithms analyze the images to identify defects, and this information mediates the sorting decision process, enabling precise defect detection while maintaining a relatively simple overall system structure
2Measurement precision
If conventional foreign matter sorting device is used for large circular objects, then imaging is easier, but there is minimal imaging range due to depth issues and cannot acquire color information from both sides of hexahedral pellets
Solution Approach 1:
The patent addresses the limitation of single-sided imaging by positioning cameras to capture images from multiple dimensions and angles during pellet transfer. The system uses the temporal dimension of continuous transfer to capture both sides of hexahedral pellets as they move through the inspection zone, enabling comprehensive color and defect detection without increasing physical imaging range
Solution Approach 2:
The patent utilizes the dynamic motion of pellets during transfer through the inspection zone. Instead of attempting to image stationary pellets from multiple positions, the system captures images of moving pellets at different moments, leveraging the continuous transfer motion to expose both sides of hexahedral pellets to the imaging system
3Productivity
If high-speed continuous transfer is implemented to process 1,200 kg per hour, then productivity increases, but there is a limit to solving quality problems due to inspection speed constraints
Solution Approach 1:
The patent implements continuous quality inspection throughout the entire pellet transfer process. Cameras continuously capture images of pellets as they move through the inspection zone, and image processing algorithms continuously analyze these images in real-time. This continuous inspection approach maintains high processing speeds while ensuring no defects are missed, resolving the conflict between productivity and quality inspection accuracy
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 system significantly improves the accuracy and efficiency of pellet inspection and sorting by detecting defects in real-time during transfer and predicting potential defects in final products, enhancing quality control.
Implementation Method 1
a first vibration generator configured to vibrate the first transfer plate at a predetermined frequency
Implementation Method 2
a first dispensing part disposed in front of the first vision inspection part to suction the pellets that are determined as being defective by the first vision inspection part
Data Source
AI summary
A system for automatically inspecting and sorting pellets while continuously transferring the pellets at a high speed to detect and effectively remove pellets that are defective. The system includes a sorter to photograph and inspect a first surface and a second surface of each of the pellets while transferring the pellets. The system separates and removes pellets that are determined as being defective and transfers and loads pellets having good quality to a designated position. The system further includes a sample inspector to receive the plurality of pellets that are determined as good products to manufacture a plate-shaped sample of a molded product and photograph a first surface and a second surface of the manufactured sample, thereby inspecting whether the sample of the molded product is defective.