Automated Shell Sorting via Optical Inspection and Ejection
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Solution Overview
Problem
Current shell sorting systems, such as those using multistage vibrating sieves and air blowers, fail to accurately separate empty shells from shells containing kernels or parts of kernels due to lack of optical inspection, resulting in significant labor, time, and resource inefficiencies.
Innovation Solution
An automated shell sorting system employing a feeder, roller pair arrangement, orientation flaps, camera boxes, and an ejection assembly to guide, orient, and optically inspect shells, allowing for precise separation of empty shells from those containing kernels or parts of kernels using cameras and controlled ejection into specific chutes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If multistage vibrating sieves are used to sort kernels from shells, then the sorting process is automated, but the system fails to separate shells having kernels or part of kernels from empty shells due to lack of optical inspection
Solution Approach 1:
The patent replaces the purely mechanical vibrating sieve system with an optically-guided ejection system. Cameras capture images of shells, optical sensors detect kernel presence, and controlled air jets or mechanical ejectors remove shells containing kernels based on optical detection, thereby achieving both automation and high precision separation.
Solution Approach 2:
The patent introduces optical sensors and cameras as intermediary detection devices between the mechanical sorting components and the shells. These intermediaries detect the presence of kernels inside shells and provide signals to the ejection mechanism, enabling precise identification and separation without direct mechanical contact during detection.
2Loss of substance
If air blowers or fans are used to force hit shells containing kernels on container walls to remove stuck kernels, then kernel removal is achieved, but significant broken kernels occur as output
Solution Approach 1:
The patent replaces the high-force mechanical impact method (air blowers forcing shells against walls) with a gentle optical detection and controlled ejection system. Cameras and sensors identify shells containing kernels, and controlled air jets or soft mechanical ejectors guide these shells to a separate collection container without causing kernel breakage.
Solution Approach 2:
The patent performs preliminary optical inspection and identification of shells containing kernels before the ejection step. By detecting kernel presence in advance using cameras and sensors, the system can prepare the appropriate ejection mechanism and direct the identified shells to a safe collection area, preventing breakage before it occurs.
3Device complexity
If conventional sorting systems without optical inspection are used, then device complexity is reduced, but the ability to accurately segregate shells having kernels from empty shells is significantly missed
Solution Approach 1:
The patent introduces cameras and optical sensors as intermediary detection devices that bridge the gap between simple mechanical sorting and complex accurate separation. These optical intermediaries detect kernel presence inside shells and provide information to the control system, enabling accurate segregation without requiring overly complex mechanical structures.
Solution Approach 2:
The patent implements a feedback loop where cameras capture images of shells, optical sensors analyze them for kernel presence, and the control system uses this information to activate ejection mechanisms for identified shells. This feedback-driven approach enables accurate detection and separation while maintaining relatively simple device architecture.
Data Source
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AI summary
Object sorting system comprising a feeder (120), a roller pair (130), a pair of orientation flaps (140), an adjustable assembly (150), first and second camera boxes (160a, 160b) and an ejection assembly (180). Feeder (120) feeds shells over the gap between the rollers (130) which provides fixed orientation to the shells passing through them and conveys the shells which are relatively bigger than the gap towards a first collection chute (190a). A pair of orientation flaps (140) is placed parallel and below the pair of rollers (130). The cameras placed below the orientation flaps (140) capture the area of interest of each oriented shell. An ejection assembly (180) is located beneath the camera boxes (160a, 160b) to eject the shells having kernel or part of the kernel stuck inside them and gets them collected in the second collection chute (190b) and remaining empty shells in the third collection chute (190c).