Vision-Guided Form Sorting for Mixed Size and Orientation Stacks
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Solution Overview
Problem
Existing form sorting systems require manual alignment and handling of forms by size, which is time-consuming and inefficient, especially when dealing with varying sizes and orientations.
Innovation Solution
A form sorting system that uses a recognition mechanism to identify forms in a stack and controls a robot to convey them to a sorting mechanism without overlapping, allowing for efficient sorting of forms of different sizes and orientations using a conveyor and sorting device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If forms are manually aligned and classified by size before being set in the hopper, then the sorting accuracy is improved, but the time and effort required for preparation increases
Solution Approach 1:
The system enables forms to be processed without manual alignment or classification. The robot automatically picks forms from the hopper regardless of their orientation or position, and the imaging device captures images to determine form types and sizes automatically. This self-service approach eliminates the need for operators to manually align and classify forms before sorting.
Solution Approach 2:
The patent replaces the manual mechanical alignment process with an automated vision-based system. The imaging device captures images of forms in the hopper, and the control unit processes these images to identify form types and sizes, replacing the need for manual mechanical alignment and classification operations.
2Device complexity
If forms of various sizes are handled with a simple mechanism, then the device complexity is reduced, but the ability to accurately sort different sizes deteriorates
Solution Approach 1:
The patent replaces complex mechanical size classification mechanisms with a vision-based identification system. The imaging device captures images of forms, and the control unit analyzes these images to determine form types and sizes, enabling accurate size classification without requiring complex mechanical sorting mechanisms.
Solution Approach 2:
The robot and conveyor system are designed to handle forms of various sizes and orientations with a single unified mechanism. The robot can pick forms regardless of their size or orientation, and the conveyor can transport forms of different dimensions, providing universal handling capability that eliminates the need for multiple specialized mechanisms for different form sizes.
3Speed
If forms are conveyed without preventing overlap, then the conveyance speed increases, but the sorting reliability deteriorates
Solution Approach 1:
The control unit determines the type and size of each form using image recognition before the form reaches the sorting position. This preliminary identification allows the system to prepare the appropriate sorting action in advance, ensuring accurate sorting even when forms are conveyed at high speeds without overlapping prevention mechanisms.
Data Source
AI summary
A form sorting system according to an aspect of the present disclosure includes: at least one memory configured to store instructions; and at least one processor configured to execute the instructions to: recognize forms placed in a stack; and control a robot based on a result of the recognition, the robot controlled to pick up one or more of the forms placed in a stack and to place each one of the one or more of the forms to a conveyor so as not to overlap with another form, wherein the conveyor conveys forms to a sorting mechanism.