Sorting System Product Type Switching
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Solution Overview
Problem
Conventional sorting systems require significant downtime for switching between product types, limiting their operational capacity due to the need to empty all channels before switching, which is time-consuming and inefficient.
Innovation Solution
A method that allows for a gradual and efficient switch between product types by selecting and assigning clear sorting channels to the new product type, utilizing a prioritization system and residual categories to optimize channel usage, and proactively emptying channels to reduce switch-over time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sorting system empties all channels before switching product types, then product contamination is prevented, but switch-over time increases significantly
Solution Approach 1:
The sorting system is divided into multiple independent sorting channels that can be managed separately. During product type switching, only the necessary channels are emptied while others remain active, segmenting the emptying operation to reduce overall switch-over time while maintaining contamination prevention in active channels
Solution Approach 2:
The system performs preliminary identification of which sorting channels will be needed for the new product type before the switch begins. Channels that will not be used are emptied in advance, while channels that will be used remain active, allowing the switch to proceed faster without risking contamination in active channels
2Adaptability or versatility
If all sorting channels are emptied before switching, then complete product type transition is achieved, but operational capacity decreases
Solution Approach 1:
Instead of emptying all sorting channels, the system performs partial emptying only of those channels that will not be used for the new product type. This partial action achieves the necessary product type transition while maintaining operational capacity in the channels that remain active
Solution Approach 2:
The system dynamically determines which sorting channels to empty based on the specific product type being switched to. The configuration of active versus emptied channels changes dynamically according to the new product type's requirements, optimizing both transition completeness and operational capacity
3Device complexity
If discharge equipment capacity is limited and shared, then system complexity is reduced, but switch-over time is prolonged
Solution Approach 1:
The system preliminarily identifies and prepares the discharge equipment needed for the new product type before the switch begins. By knowing in advance which channels will be active, the system can prepare the shared discharge equipment accordingly, reducing wait time during the actual switch while maintaining the simple shared equipment configuration
Data Source
Figure 1
Figure 2A~2C
Figure 3A~3C
AI summary
The invention relates to a method for switching between different products such as vegetables and fruit on a sorting system, a computer-readable medium and sorting system suitable therefor, the method comprising of: - receiving a switching signal during sorting of products of the first product type that products of the second product type have to be sorted; - the controller selecting sorting channels which are free of products of the first product type; - assigning at least some selected sorting channels to the second product type; - assigning sorting classes of the second product type to one or more of the assigned sorting channels; and - sorting products of the second product type in sorting channels assigned thereto during the emptying of sorting channels of the first product type. Preparatory emptying of some of the sorting channels optionally takes place prior to the switch-over.