Roller System for Produce Sorting with Stem Gaps
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Solution Overview
Problem
Conventional produce conveyor systems fail to adequately expose all surfaces of smaller and stemmed produce, such as cherries or blueberries, during optical scanning and sorting, as the stem impedes unrestricted positioning and rotation, limiting the effectiveness of automated optical scanning systems.
Innovation Solution
A roller system with paired roller trucks and conveyor chains that allow for the rotation of produce within a produce pocket, featuring a spindle gap for the stem to pass through, ensuring all surfaces are exposed to optical scanners, utilizing a roller drive belt and motor-driven pulley system for continuous rotation and advancement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional conveyor systems are used to move produce, then the produce can be transported through the sorting system, but the stem of the produce impedes unrestricted positioning and rotation, limiting the exposure of all produce surfaces to optical scanners
Solution Approach 1:
The conveyor system is segmented into multiple rollers arranged in specific patterns (e.g., V-shaped, circular) rather than a single continuous belt. This segmentation allows individual rollers to independently control and rotate produce items, enabling the stem to pass through gaps between rollers while the fruit body is rotated to expose all surfaces to scanners.
Solution Approach 2:
The roller system acts as an intermediary mechanism between the produce and the optical scanner. By using multiple rollers with strategic spacing, the system mediates the conflict between the stem's presence and the need for full surface exposure, allowing the stem to pass through gaps while the fruit is rotated into optimal scanning positions.
2Measurement precision
If produce is rotated to expose all surfaces to optical scanners, then scanning quality improves, but the stem impedes the rotation and positioning of the produce on conventional conveyors
Solution Approach 1:
The conveyor system transitions from a static belt to a dynamic roller system where individual rollers can be independently controlled. This allows the produce to be actively rotated and positioned during conveyance, ensuring all surfaces are exposed to scanners while the stem passes through gaps between rollers.
Solution Approach 2:
The system adds rotational movement as another dimension of motion beyond simple linear conveyance. By arranging rollers in three-dimensional patterns (e.g., V-shapes, circles), the system enables produce to rotate around multiple axes, exposing all surfaces to scanners from different angles while accommodating the stem's presence.
3Productivity
If conventional belts or chains are used to convey produce, then the produce can be moved through the system, but they fail to adequately expose all produce surfaces, especially for smaller and stemmed produce
Solution Approach 1:
The continuous belt or chain is segmented into discrete rollers that can independently move and rotate produce items. This segmentation allows each produce item to be individually positioned and rotated to expose all surfaces to scanners, while the gaps between rollers accommodate stems and allow for unrestricted movement.
Solution Approach 2:
The roller system implements periodic rotation and positioning actions to ensure all surfaces of each produce item are exposed to scanners. The rollers sequentially rotate the produce through different orientations, providing periodic exposure of different surfaces to the optical scanning system.
Data Source
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AI summary
A roller system (15) for sorting a produce or fruit (116), with a conveyor (24) having an upper run and a lower run, a roller truck (20) with two spindles (32) and a roller drive wheel (30) between. The roller truck (20) is attached to side-by-side conveyors (24) each with a string of the roller trucks (20) operating in parallel and a roller drive belt (33) contacting the roller drive wheel (30) of the roller truck (20) on the upper run, to spin the roller drive wheel (30) and the roller pair (25). The side-by-side roller pairs (25) of spindles (32) have a spindle gap (G) between each pair (14) and a pocket (P) is formed between each of roller pairs (25) for receiving the produce (116), such as cherries, nuts or blueberries. As the roller drive belt (33) rotates the roller wheel (30), the produce (116) is rolled and repositioned in the pocket (P), exposing and presenting all surfaces of the produce (116) to an optical scanner (155).