Automated Sorting System with Multi-Angle Imaging for Nonstandard Item Isolation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing sorting systems are labor-intensive, expensive, and lack accuracy in sorting products, especially those with irregular shapes, requiring manual manipulation and longer sorting times to achieve desired precision.
Innovation Solution
A sorting system and method utilizing an item carrier with zones for charging, detection, and sorting, where items are imaged from different angles to identify nonstandard items, and a picking system isolates these items based on image analysis, with rollers and orientation-changing zones to facilitate accurate sorting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual removal and manipulation of items are used for sorting, then sorting accuracy can be improved, but labor intensity and operating costs increase
Solution Approach 1:
The patent replaces manual mechanical manipulation with an automated imaging and identification system. Multiple images are captured from different angles, processed to identify nonstandard items, and then robotic pickers automatically remove these items, eliminating the need for manual labor while maintaining high sorting accuracy.
Solution Approach 2:
The system creates optical copies (images) of the items from multiple angles and positions. These image copies are then analyzed to identify nonstandard items without requiring physical manual inspection, enabling automated decision-making for sorting.
2Measurement precision
If multiple images are captured from different angles to identify nonstandard items, then sorting accuracy is improved, but system complexity and cost increase
Solution Approach 1:
The detection zone is divided into multiple segments (first detection zone with first imaging device, second detection zone with second imaging device). Each segment captures images from different angles, and the results are combined to improve identification accuracy while keeping each individual imaging device relatively simple.
Solution Approach 2:
The system adds spatial dimensions to image capture by placing imaging devices at different positions and angles. The first imaging device captures images from one angle while the second imaging device captures images from another angle, creating a multi-dimensional view that improves identification accuracy.
3Measurement precision
If items are physically distanced and oriented for better imaging, then image quality and sorting accuracy improve, but the time required for sorting increases
Solution Approach 1:
Items are pre-oriented and physically distanced in the charging zone before entering the detection zone. This preliminary arrangement ensures that when items reach the imaging devices, they are already in optimal positions for capture, eliminating the need for time-consuming repositioning during detection and reducing overall sorting time.
Solution Approach 2:
The system maintains continuous item flow through the charging zone, detection zone, and sorting zone. Items are continuously oriented and imaged without interruption, and nonstandard items are continuously identified and removed, ensuring that the useful action of sorting proceeds without breaks or delays.
4Extent of automation
If nonstandard items are isolated using automated picking systems, then labor costs are reduced, but device complexity and initial investment increase
Solution Approach 1:
The patent introduces robotic pickers as intermediary devices between the detection zone and sorting zone. These pickers receive identification information from the imaging system and automatically execute the removal of nonstandard items, serving as a mediator that translates detection data into physical sorting action without requiring human intervention.
Data Source
AI summary
The present disclosure concerns a method for sorting items transported along a conveyance direction on an item carrier of a sorting system, the item carrier comprising a charging zone, a first detection zone, an item orientation-changing zone, a second detection zone and a sorting zone, the method comprising sequentially: loading the items on the item carrier in the charging zone; capturing a first image of the items in the first detection zone; changing an orientation of the items in the item orientation-changing zone, located downstream of the first detection zone; capturing a second image of the items in the second detection zone, located downstream of the first detection zone; identifying nonstandard items amongst the items from information derived from the first and second images; and isolating the identified nonstandard items in the sorting zone. It also concerns a corresponding sorting system.