Object Sorting Buffer and Sequencing for Customized Parts
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Solution Overview
Problem
Current sorting devices are inefficient in handling and packaging unique or customized parts, requiring manual intervention to ensure accuracy, which hampers productivity and efficiency in mass production processes.
Innovation Solution
A system that includes a load cell for part distribution, a vision system for orientation and identification, a sorting buffer for grouping, and a sequencing system to accumulate and arrange parts correctly, utilizing RFID tagging and conveyor systems for automated sorting and packaging of mass-produced customized objects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated sorting devices are used for mass produced parts, then productivity is improved, but they cannot handle unique or customized parts requiring manual intervention
Solution Approach 1:
The sorting system is designed to handle both standardized and customized parts through a universal platform. The system uses RFID tags for identification and a combination of automated sorting mechanisms that can adapt to different part types, allowing a single system to perform multiple sorting functions without requiring manual intervention for customized parts.
Solution Approach 2:
The system enables customized parts to be automatically identified, sorted, and packaged through self-service mechanisms. RFID readers automatically detect part identities, the control system determines appropriate sorting destinations, and the sorting mechanisms automatically direct parts to correct locations, eliminating the need for manual handling even for unique customized components.
2Reliability
If manual sorting is used for customized parts, then accuracy is improved, but productivity and efficiency deteriorate
Solution Approach 1:
The system replaces manual mechanical sorting with an automated control system that uses RFID technology for identification, electronic control for decision-making, and automated sorting mechanisms for physical separation. This substitution maintains high accuracy in identifying and sorting customized parts while dramatically improving productivity by eliminating manual labor bottlenecks.
Solution Approach 2:
The system incorporates feedback loops where RFID readers continuously identify parts, the control system processes this information to determine correct sorting destinations, and the sorting mechanisms execute the sorting action. The system monitors the sorting process and can adjust its operations to ensure accurate grouping and sequencing of customized parts, maintaining reliability while operating at automated speeds.
Data Source
AI summary
Methods for sorting and sequencing objects are provided. In some embodiments, a method includes receiving a plurality of objects, each object associated with an identifier including group data identifying a group to which the object belongs, and sequence data identifying a sequential position for the object within the group. The method can include determining the group data and the sequence data for each object by reading the identifier associated with the object; sorting the plurality of objects by directing each object into one of a plurality of buffer locations based on the group data for the object; and sequencing the set of objects associated with each buffer location by placing each object into a position within the corresponding set of objects based on the sequence data for the object.