Sorting Device for Bulk Products Using Image-Based Engagement Points
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Solution Overview
Problem
Current automated sorting devices are inefficient in separating products from a random bulk stream of inhomogeneous products, leading to a significant proportion of defective products remaining unsuitable for sale or further processing, and satisfactory products being undeservedly discarded.
Innovation Solution
A sorting device that incorporates an image recording unit, image processing unit, decision unit, object processing unit, and control unit to determine product and process properties, allowing for precise identification of points of engagement for efficient separation, considering both product properties (such as shape and internal quality) and process properties (like location and orientation) to improve the separation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated sorting devices use conventional optical detection and blasting systems, then separation speed is improved, but separation accuracy deteriorates leading to defective products remaining or satisfactory products being discarded
Solution Approach 1:
The system performs preliminary actions by determining process properties (position, orientation, clustering) and product properties (shape, size, weight distribution) before separation. The object processing unit calculates optimal engagement points and selects appropriate separating means in advance, ensuring accurate separation when the product reaches the separation zone, thus maintaining both high speed and high accuracy
Solution Approach 2:
The system changes parameters by considering both process properties (conveying speed, product position, orientation) and product properties (shape, size, weight distribution) to dynamically adjust separation parameters. The control unit selects from multiple separating means (blasting, mechanical fingers, pins, grippers) based on determined parameters, optimizing separation accuracy for each specific product configuration while maintaining high throughput
2Device complexity
If conventional sorting systems separate products without considering process properties, then device complexity is reduced, but separation efficiency deteriorates
Solution Approach 1:
The system achieves universality by using a single integrated object processing unit that handles multiple functions: determining process properties, determining product properties, calculating engagement points, selecting separating means, and controlling the separation process. This multi-functional approach maintains relatively simple device structure while significantly improving separation efficiency through intelligent processing
Solution Approach 2:
The object processing unit acts as an intermediary between the image recording unit and the separating means. It receives image data, processes both process and product properties, determines optimal engagement points, and controls the appropriate separating means. This intermediary layer enables efficient separation without requiring complex direct control systems
3Speed
If air blasting is used for separating products, then separation speed is improved, but energy consumption increases
Solution Approach 1:
The system changes the parameter of separating means selection based on determined product and process properties. Instead of always using energy-intensive air blasting, the control unit selects from multiple options including mechanical fingers, pins, or grippers when appropriate. This parameter-based selection optimizes energy consumption while maintaining separation speed by using the most efficient method for each specific product configuration
Solution Approach 2:
The system applies local quality by determining specific engagement points on each product based on its shape, size, and position. The separating means is targeted precisely at the determined engagement point rather than using broad-area blasting, reducing energy consumption while maintaining effective separation speed through localized, precise action
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
The solution enables more efficient separation of products by determining optimal points of engagement based on both product and process properties, enhancing the reliability and quality of the sorting process, reducing energy consumption, and minimizing errors, thus improving the overall efficiency and accuracy of the sorting device.
Implementation Method 1
an image recording unit arranged for recording images of the bulk stream of products
Implementation Method 2
an air blast is directed towards the product to be separated via this valve or these valves. The product to be separated is then 'blasted' from the bulk stream of products by means of this air blast.
Data Source
Figure 1
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AI summary
A sorting device 10 and a method for separating products in a random bulk stream 12 of inhomogeneous products 13, 14. The sorting device 10 comprises an image recording unit 4, 15 arranged for recording images of the bulk stream 12 of products 13, 14. An image processing unit 3 connected to the image recording unit 4, 15 for determining product properties and process properties of products 13, 14 in the bulk stream 12 from the recorded images. A decision unit 2 connected to the image processing unit 3 for determining, on the basis of one or more of the determined product properties of the products 13, 14, which products 13 are to be separated. A separating unit 6, 25 arranged for separating the products 13 to be separated from the bulk stream 12. As well as an object processing unit 1 arranged for determining, on the basis of one or more of the determined product properties and one or more of the determined process properties of the products 13, 14, points of engagement on the products to be separated for separating the products 13 to be separated by means of the separating unit 6, 25.