Postal Object Singulator with Dual Sensor Barrier for Transparent Film
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Solution Overview
Problem
Existing singulator devices for postal objects coated with transparent film fail to accurately calculate the spacing between objects, leading to potential contact during motion, especially at sorting exchanges, as the edges of the transparent envelope are not detected by traditional sensors, resulting in insufficient gaps.
Innovation Solution
A singulator device equipped with a dual sensor system, where a first barrier detects the postal object and a second barrier detects the transparent envelope, allowing electronic control to calculate and maintain a correct gap between the edges of the envelopes, ensuring proper spacing through a correction time mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single barrier of sensors is used to detect postal objects, then the device complexity is reduced, but the measurement precision of the gap between objects coated with transparent film deteriorates because the sensor edges cannot detect the transparent envelope edges
Solution Approach 1:
The single sensor barrier is segmented into two separate barriers: a first barrier for detecting the postal object and a second barrier for detecting the transparent envelope. This segmentation allows each barrier to perform its specific detection function, with the first barrier detecting the object edges and the second barrier detecting the envelope edges, thereby resolving the measurement precision issue while maintaining manageable device complexity through modular design
Solution Approach 2:
The transparent envelope acts as an intermediary element between the postal object and the external environment. By introducing a second sensor barrier that specifically detects this intermediary (the envelope edges rather than the object edges), the system can accurately measure the gap between envelopes even when the underlying object is not directly visible to the sensors
2Productivity
If the gap is calculated based on postal object dimensions only, then the calculation speed is improved, but the reliability of the singulation process deteriorates because the transparent envelope edges are not accounted for, causing objects to contact during motion
Solution Approach 1:
The system performs preliminary detection of both the postal object edges (via the first barrier) and the transparent envelope edges (via the second barrier) before the singulation calculation is finalized. This preliminary action allows the control system to obtain accurate dimensional data including the envelope dimensions, which are then used to calculate the appropriate gap and maintain reliable singulation throughout the motion process
Solution Approach 2:
The dual barrier sensor system provides feedback signals that contain information about both the postal object position and the transparent envelope position. This feedback is fed back to the control system, which uses it to dynamically adjust and maintain the correct gap calculation, ensuring that the singulation remains reliable even as objects move through the system
3Ease of operation
If traditional single sensor barriers are used, then the ease of operation is maintained, but the manufacturing precision of the gap between envelopes deteriorates because the envelope dimensions are not detected
Solution Approach 1:
The sensor system is segmented into two functional units: a first barrier for object detection and a second barrier for envelope detection. This segmentation allows each barrier to be optimized for its specific detection task while maintaining overall system ease of operation through modular architecture. The control system receives separate signals from each barrier and processes them to achieve precise gap control
Solution Approach 2:
The dual barrier system serves multiple functions: the first barrier detects postal object edges for basic positioning, while the second barrier detects transparent envelope edges for precise gap control. This multi-functionality allows the system to maintain ease of operation by using a standardized sensor barrier design while achieving enhanced manufacturing precision through the additional detection capability
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
The device effectively maintains a constant gap between singulated postal objects coated with transparent film, preventing contact and ensuring smooth conveying by accurately accounting for the envelope dimensions, thereby enhancing the reliability of the sorting process.
Implementation Method 1
a first barrier of n emitter/receiver sensors C (C0, C1, C2, ....Cn) arranged along the unloading path and configured for detecting passage of the postal object that moves along the unloading path; a second barrier of m emitter/receiver sensors F (F0, F1, F2, ....Fm) arranged along the unloading path and configured for detecting passage of the transparent envelope containing the postal object that moves along the unloading path
Data Source
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AI summary
A singulator device for flat rectangular postal objects coated with transparent film in which a pack of postal objects is fed to a singulator system (10) provided with a motor-driven withdrawing belt (19) for withdrawing individually the postal objects from a front face of the pack and feeding them along an unloading path (L). A first barrier of n emitter/receiver sensors C (C0, C1, C2, ... . Cn) is set aligned along the unloading path and is designed to detect the movement of edges of the postal object along the unloading path and a second barrier of m emitter/receiver sensors F (F0, F1, F2, ... . Fm) is set aligned along the unloading path and is designed to detect passage of the edges of the transparent rectangular envelope containing the postal object along the unloading path. Electronic means are provided, designed to control the motion of the withdrawing belt (19) as a function of the signals coming from the first barrier and from the second barrier for creating a constant gap between the transparent rectangular envelopes of the postal objects singulated in succession.