Vision-Based Recyclable Sorting With Timed Pusher Diversion
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Solution Overview
Problem
Conventional recycling center sorting systems are inflexible, large, and unable to efficiently handle various types of recyclable materials, lacking the ability to adapt to new materials and efficiently sort items like plastic bottles, aluminum cans, and cardboard.
Innovation Solution
A system comprising an imaging sensor, a controller with a processor and memory, and pusher devices that use machine learning to identify and divert recyclable items on a conveyor belt by processing image data and generating actuation signals to direct items into appropriate bins, allowing for dynamic reconfiguration and efficient sorting of different materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional sorting systems are used, then sorting capability is provided, but the systems are large in size and lack flexibility
Solution Approach 1:
The patent replaces complex mechanical sorting systems with a vision-based detection system and controlled pusher mechanism. The system uses imaging sensors to detect objects and a processor to identify target items, then actuates pusher devices to divert selected objects. This substitution of mechanical complexity with electronic control and image processing achieves high flexibility and adaptability while reducing overall system size.
Solution Approach 2:
The sorting system is designed with universal applicability to handle various types of recyclable materials including plastic bottles, aluminum cans, and cardboard cartons. The imaging sensor and processor combination can be configured to identify different material types through programming and image analysis algorithms, allowing a single system design to perform multiple sorting functions across different recycling facilities.
2Adaptability or versatility
If conventional sorting systems are used, then sorting is performed, but they lack the ability to be readily updated to handle new or different materials
Solution Approach 1:
The system incorporates dynamic adaptability through software-based object identification algorithms that can be updated and reconfigured to recognize new material types. The processor executes image analysis routines that can be modified through programming updates, allowing the system to adapt to new recyclable materials without hardware changes. This dynamic software configuration enables continuous upgradability while maintaining system simplicity.
Solution Approach 2:
The system allows parameter changes in the form of adjustable identification criteria and sorting rules stored in the processor. By modifying the parameters and thresholds in the image recognition algorithms and sorting logic, the system can be quickly reconfigured to handle different material types and sorting requirements, providing upgradability without increasing physical system complexity.
3Productivity
If manual sorting is used, then various materials can be handled, but the process is time-consuming and less efficient
Solution Approach 1:
The patent replaces manual sorting operations with an automated vision-based detection and control system. Imaging sensors capture images of objects on the conveyor, the processor rapidly analyzes the images to identify target items, and pusher devices automatically divert selected objects. This automation eliminates the time consumption of manual inspection and sorting, dramatically increasing productivity while reducing sorting time per item.
Solution Approach 2:
The system performs preliminary detection and identification of target items before they reach the diversion point. The imaging sensor captures images upstream, the processor analyzes and identifies target objects in advance, and the control system prepares actuation signals before the objects arrive at the pusher devices. This preliminary action sequence enables rapid sorting without slowing down the conveyor, maximizing productivity.
Data Source
AI summary
Systems and methods for sorting recyclable items and other materials are provided. In one embodiment, a system for sorting objects comprises: at least one imaging sensor; a controller comprising a processor and memory storage, wherein the controller receives image data captured by the image sensor; and at least one pusher device coupled to the controller, wherein the at least one pusher device is configured to receive an actuation signal from the controller. The processor is configured to detect objects travelling on a conveyor device and recognize at least one target item traveling on a conveyor device by processing the image data and to determine an expected time when the at least one target item will be located within a diversion path of the pusher device. The controller selectively generates the actuation signal based on whether a sensed object detected in the image data comprise the at least one target item.