Sorting Machine Flat Articles Edge Bunching Detection
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Solution Overview
Problem
Existing sorting machines for flat articles face challenges in reliably detecting bunching, particularly with fragile or wrapped items, leading to potential damage and costly misidentification during the sorting process.
Innovation Solution
A sorting machine with an intermediate conveyor featuring perforated belts and suction means, along with image capture and analysis, allows for independent detection of bunching without nipping, enabling lateral separation and reducing shear forces, thus enhancing detection reliability and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If nipping is used to convey flat articles in the downstream conveyor, then conveying reliability is improved, but detection accuracy of bunching deteriorates due to shear forces and article deformation
Solution Approach 1:
The conveyor system is segmented into two independent sections: an upstream conveyor with nipping belts for reliable conveying, and a downstream conveyor with open belts for accurate detection. This segmentation allows each section to perform its specific function optimally without interference from nipping forces during the detection phase.
Solution Approach 2:
The downstream conveyor acts as an intermediary detection zone between the upstream nipping conveyor and the sorting mechanism. It provides a transition area where articles can be observed in their natural state without the distorting effects of nipping, enabling accurate bunching detection before articles return to the nipping conveyor for sorting.
2Productivity
If shear force is applied to separate bunched flat articles, then bunching separation is improved, but article integrity deteriorates due to damage to fragile items
Solution Approach 1:
The mechanical shear force separation method is replaced with an optical detection system using cameras and image processing. Bunched articles are identified through image analysis of their lateral displacement on the open belts, eliminating the need for physical separation forces that could damage fragile articles.
Solution Approach 2:
Instead of physically separating bunched articles through mechanical force, the system creates an optical copy (image) of the article arrangement and analyzes this copy to identify bunching. The digital representation allows for accurate detection without applying any physical stress to the original articles.
3Ease of operation
If nipping is used during detection, then conveying control is improved, but detection reliability deteriorates due to misidentification of wrapped articles
Solution Approach 1:
The belt configuration dynamically changes based on the operational phase: the downstream conveyor belts are opened during the detection phase to eliminate nipping effects, and can be closed during the conveying phase to provide nipping control. This dynamic adjustment allows the system to optimize for detection reliability when cameras are active.
4Measurement precision
If open belts are used instead of nipping belts for downstream conveyance, then detection accuracy is improved, but conveying efficiency deteriorates
Solution Approach 1:
The downstream conveyor belts operate in periodic cycles, alternating between open configuration for detection and closed configuration for efficient conveying. During detection phases, belts remain open to allow accurate imaging; during conveying phases, belts close to provide nipping and maintain conveying efficiency, thus balancing both requirements.
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 effectively detects bunching and separates flat articles without damaging them, reducing erroneous detections and improving the handling of fragile items, particularly those wrapped in transparent plastic or with printing artifacts.
Implementation Method 1
suction means associated individually with the intermediate belts and suitable for generating suction at each of the intermediate belts, which suction is suitable for pressing any flat article traveling between the intermediate belts against one or the other of the intermediate belts
Data Source
AI summary
A sorting machine (1) for sorting flat articles (2) on edge, which machine includes an upstream conveyor (10), and a downstream conveyor (30) that conveys the flat articles (2) by nipping them, the upstream conveyor (10) and the downstream conveyor (30) being separated by detector means (100) including an intermediate conveyor (20) provided with intermediate belts (22) that convey said flat articles (2) by nipping them, and that are associated individually with suction means (24, 25) pressing any flat article (2) against one or the other of said intermediate belts (22), image capture means (26) for capturing images of the bottoms of said flat articles (2) passing between the intermediate belts (22), and analysis and processing means (4) for analyzing and processing said images to detect any bunching of said flat articles (2).