Sorter Element Synchronization via Image Comparison
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Solution Overview
Problem
There is a lack of reliable and cost-effective methods for synchronizing the information of sorted items with sorter elements during manual loading in sorting and distribution systems, particularly when voice coding is used, as existing methods fail to unambiguously assign the item information to the correct sorter element.
Innovation Solution
The method employs image recording and analysis technology by capturing images before and after the placement area of each sorter element, using cameras to recognize occupancy and assign item information to the correct sorter element, even for minimal thicknesses of goods, and incorporates voice input for direct manual delivery, reducing hardware and space costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If image recording and analysis technology is used to capture images before and after the placement area, then the reliability of synchronizing item information with sorter elements is improved, but the device complexity and cost increase due to additional cameras and image processing systems
Solution Approach 1:
The patent uses image recording to create visual copies of the placement area before and after sorting operations. These image copies are then analyzed to detect item placement and synchronize information without requiring direct physical interaction or complex mechanical sensing systems at the placement area itself.
Solution Approach 2:
The patent replaces potential mechanical or electronic sensing systems with optical image recording and analysis. Instead of using sensors, switches, or mechanical detectors to identify item placement, the system uses cameras to capture images and software to analyze them, substituting mechanical detection with optical-field-based detection.
2Ease of operation
If voice coding is used for manual loading, then the ease of operation is improved, but the reliability of assigning item information to the correct sorter element deteriorates due to ambiguity in voice input
Solution Approach 1:
The patent implements a feedback mechanism where image recording provides visual confirmation of item placement. This feedback loop allows the system to verify that the item mentioned in voice input has actually been placed on the correct sorter element, thereby resolving ambiguity and ensuring reliable information assignment while maintaining the ease of voice-based operation.
Solution Approach 2:
The patent introduces image analysis as an intermediary between voice input and information assignment. Instead of directly assigning information based on voice commands alone, the system uses image analysis results as an intermediate verification step to confirm item placement, thereby ensuring reliable assignment while preserving the ease of voice-based operation.
3Measurement precision
If light barrier or light grid arrangements are used to detect sorted goods, then the measurement precision is improved, but the ability to detect minimal thicknesses of goods deteriorates
Solution Approach 1:
The patent transitions from one-dimensional detection methods like light barriers that measure presence/absence along a single line, to two-dimensional image recording that captures spatial information across an area. This dimensional change allows detection of minimal thicknesses by analyzing pixel-level variations in the captured images, providing both precision and versatility.
Solution Approach 2:
The patent changes the detection parameter from simple light interruption (binary presence/absence) to detailed image intensity and spatial distribution data. By analyzing multiple parameters from the image data such as pixel brightness, edge detection, and spatial patterns, the system can detect minimal thicknesses of goods that would be invisible to simple light barriers while maintaining high measurement precision.
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 approach creates a cost-effective and reliable system for synchronizing sorting goods information with sorter elements, enabling accurate assignment and monitoring of operator performance, and ensuring correct sorting by comparing images and integrating voice input for manual loading scenarios.
Implementation Method 1
at least before and after the item to be sorted is placed on a sorting element, a picture of the support area of each sorting element is taken
Implementation Method 2
the occupancy of the sorting element with a item to be sorted is recognized by image comparison
Data Source
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AI summary
The method involves preparing an image from the overlay of a sorter element (3) before and after the feeding of the sorted material at the sorter element. The occupancy of this sorter element with the sorted material is detected by image comparison. The information identified before the feeding about the sorted material is definitely assigned to the sorter element identified as fed. An independent claim is included for a sorting and distribution system, which has an arrangement for synchronization of distributing information of a sorted material.