Segmented Conveyor Rejection for Precise Width-Based Sorting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current sorting or rejection systems with fixed apertures are inefficient as they divert both disqualified and qualified products when processing lines increase in width, leading to waste and inefficiency.
Innovation Solution
A conveyor system with a diverter system comprising adjustable diverter segments that analyze and respond to the location and size of each work product, diverting only non-compliant products while allowing compliant ones to continue on the processing path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a fixed aperture rejection system is used, then the system structure is simple, but as processing lines increase in width, qualified product is inadvertently diverted along with disqualified product
Solution Approach 1:
The rejection system is divided into multiple independently controllable diverter segments arranged across the width of the conveyor. Each segment can be selectively activated to divert only the specific portion of product that needs rejection, rather than using a single fixed aperture that diverts the entire width. This segmentation allows precise control over which products are diverted while maintaining system simplicity.
Solution Approach 2:
The diverter segments transition from a static fixed aperture design to a dynamic adjustable system. The segments can be actuated individually based on the location and size of disqualified products detected by scanners, allowing the rejection system to adapt to different product positions and sizes. This dynamic capability prevents qualified products from being diverted while maintaining the ability to reject disqualified products effectively.
2Ease of operation
If a fixed aperture rejection system is used, then the system operation is simple, but sorting precision decreases as conveyor width increases
Solution Approach 1:
The aperture is segmented into multiple controllable sections that can be independently activated. This allows the system to maintain simple operation through automated control while achieving high sorting precision by targeting specific segments for rejection based on product location and size, rather than using a single fixed aperture that affects the entire conveyor width.
Solution Approach 2:
Scanners detect the location and size of products and provide feedback to the control system, which then activates the appropriate diverter segments. This feedback mechanism enables the system to maintain high sorting precision by dynamically adjusting which segments are active based on real-time product characteristics, while keeping the operation simple through automation.
3Reliability
If the aperture width is increased to cover the full conveyor width, then all products are captured for rejection, but qualified products are also diverted
Solution Approach 1:
The full aperture width is segmented into multiple smaller segments that can be selectively activated. This allows the system to maintain reliable rejection by capturing all potential disqualified products through the segmented structure, while improving productivity by activating only the necessary segments for each rejection event, thereby minimizing interruptions to the conveyance throughput of qualified products.
Solution Approach 2:
Instead of activating the full aperture width for every rejection event, the system uses partial action by activating only the specific segments needed for each disqualified product. This approach ensures reliable rejection of disqualified products while avoiding excessive action that would unnecessarily divert qualified products and reduce conveyance throughput.
4Loss of substance
If multiple diverter segments are used to improve sorting precision, then qualified product waste is reduced, but device complexity increases
Solution Approach 1:
The diverter system is segmented into multiple independent segments that can be controlled individually. This segmentation reduces qualified product waste by enabling precise targeting of rejected products, while the modular nature of the segments keeps the overall device complexity manageable compared to a single complex fixed aperture system.
Solution Approach 2:
The diverter segments are designed to be universally applicable across different product sizes and positions. Each segment can function independently to handle various rejection scenarios, making the system multi-functional and reducing the need for additional specialized components, thereby limiting the increase in device complexity while achieving reduced qualified product waste.
Data Source
AI summary
Food products (22) being transported on a conveyor (24) are scanned to ascertain if designated desired physical parameters are met. If so, the food products (22) are allowed to continue along a processing path. If not, the food products are diverted from the processing path by a diverter system (30) consisting of the plurality of individually operated diverter units positioned across the width of the conveyor. The diverter units (32) are controlled by a control system (28) so that only the diverter units in alignment with work products (22) to be diverted are actuated thereby to remove the work product from the processing path (25).