EP4635640A1

EP4635640A1 - Pellet sorting method and device, and its pellet flow channel

Info

Publication number: EP4635640A1
Application number: EP24171193.6A
Authority: EP
Inventors: Jen-Yi Hsieh
Original assignee: Okimation Inc
Current assignee: Okimation Inc
Priority date: 2024-04-19
Filing date: 2024-04-19
Publication date: 2025-10-22

Abstract

A pellet sorting method and device, and its pellet flow channel comprising: feeding a plurality of pellets (16) into the pellet flow channel (10) and providing a first airflow (35) and a second airflow (36) to the pellet flow channel (10). Controlling the presence, angle, direction, flow rate, and frequency of the first airflow (35) and the second airflow (36) thereby inducing and controlling the plurality of pellets (16) to undergo motion such as rolling, rotating, tumbling or maintaining momentarily stillness. This allows an optical camera (18) to comprehensively capture all directional multi-angles' images of the plurality of pellets (16) in the pellet flow channel (10), which are then sent to a digital image data processor for identification and analysis. If it is determined that all the plurality of pellets (16) meet predetermined conditions, all the plurality of pellets (16) direct to the first collection path (21). If one or more the plurality of pellets (16) are determined to not meet the predetermined conditions, the first airflow (35) is instantaneously air pneumatic ejected at high speed, directing all the plurality of pellets (16) toward the second collection path (23).

Description

Technical Field

The disclosure relates to a pellet sorting method and device technology.

Background

Please refer FIG. 1, the CN112837311A disclose a polyethylene pellet defect detection and identification system comprising: a control unit 100, a feeding unit 200, an identification unit 300, a screening unit 500, and a collection component 400. The feeding unit 200 is used to allow polyethylene pellets P to fall in a waterfall-like manner. The identification unit 300 includes several multimodal cameras 310, as well as an AI processor 320 connected to each multimodal camera 310. Each multimodal camera 310 is located on one side of the falling path 600 of the polyethylene pellets, used to capture images of each polyethylene pellet P and send them to the AI processor 320. The AI processor 320 is connected to the control unit 100 and is used to identify polyethylene pellets P with defects and send them to the control unit 100. The screening unit 500 includes several air jet nozzles 510 connected to an air compressor 520, positioned on the other side of the falling path 600 of the polyethylene pellets. Each air jet nozzle 510 is controlled by the control unit 100 to open or close, blowing defective polyethylene pellets P off the falling path 600. The collection component 400 comprises a normal pellet collection unit 410 and a defective pellet collection unit 420, respectively used to collect defect-free polyethylene pellets and defective polyethylene pellets.
The main drawbacks of the aforementioned prior art are as follows: the polyethylene pellets P fall in a free-fall manner in the falling path 600, and it is unpredictable whether or when the polyethylene pellets P will roll during their descent in the falling path 600. This leads to difficulties in capturing comprehensive all directional multi-angle's images of pellets, making it challenging for the previous invention to anticipate and capture rolling pellet images effectively and correctly. Therefore, previous technologies attempted to address this issue by employing multiple multimodal cameras 310 and complex recognition techniques. However, these multimodal cameras 310 are all located only on the same side of the pellet's falling path 600, making it difficult to capture all directional multi-angles' images of pellets. As a result, the AI processor 320 will not be able to accurately identify all defective pellets from different angles.

SUMMARY

To address the aforementioned invention issues, this invention proposes a pellet sorting method and device. This method and device actively induce and control a plurality of pellets to undergo rolling, rotating, tumbling, or maintaining momentarily stillness within the pellet flow channel. This facilitates comprehensive all directional multi-angles' images of the plurality of pellets captured by an optical camera, thereby improving the accuracy and precision of the pellet purity and defective analysis. The detailed invention content is described as follows.

Technical features of the invention:

A pellet sorting method, comprising: feeding a plurality of pellets into a pellet flow channel; the pellet flow channel is enclosed and transparent with both open ends; supplying a first airflow and a second airflow to the pellet flow channel, the first airflow jets from the first end of the pellet flow channel to the second end, causing the plurality of pellets to move from the first end to the second end of the pellet flow channel; the second airflow jets from the second end of the pellet flow channel towards the first end, inducing and controlling the plurality of pellets by the first airflow and second airflow to make them roll, rotate, tumble, or maintain momentarily stillness as they pass through the pellet flow channel; using an optical camera to comprehensively capture all directional multi-angles' images of the plurality of pellets from the pellet flow channel, and sending these captured images to an digital image data processor for identification and analysis; if the identification and analysis result determines that all the plurality of pellets meet a preset conditions, all the plurality of pellets directed to a first collection path; if the identification and analysis result determines that one or more of the plurality of pellets do not meet the preset conditions, the first airflow is instantaneously air pneumatic ejected at high speed, directing all the plurality of pellets in the pellet flow channel towards a second collection path.
In a preferred embodiment, the pellet sorting method, further comprising a third airflow, which jets from the second end of the pellet towards the second collection path, in coordination with the high-speed air pneumatic ejection of the first airflow to direct all the plurality of pellets towards the second collection path.
In a preferred embodiment, the first airflow jets from the first end to the second end of the pellet flow channel in a lower section of the pellet flow channel, while the second airflow jets from the second end to the first end of the pellet flow channel in an upper section of the pellet flow channel.
A pellet sorting device, comprising: a pellet flow channel which is enclosed and transparent with both open ends; a feeding unit feeds a plurality of pellets from the first end of the pellet flow channel to the pellet flow channel; an air flow unit comprising a first air jet nozzle and a second air jet nozzle, which provide a first airflow and a second airflow to the pellet flow channel, respectively, the first airflow jets from the first end of the pellet flow channel towards the second end, causing the plurality of pellets to move from the first end to the second end of the pellet flow channel, the second airflow jets towards the pellet flow channel from the second end, inducing and controlling the plurality of pellets to roll, rotate, tumble, or maintain momentarily stillness as it passes through the pellet flow channel; a first collection path connected to the second end of the pellet flow channel; a second collection path connected to the second end of the pellet flow channel; a diverter switch controlling the opening of either the first or the second collection path; an optical camera for comprehensive captured all directional multi-angles' images of the plurality of pellets in the pellet flow channel, sending these images to an digital image data processor for identification and analysis; if all the plurality of pellets are identified to meet preset conditions, the diverter switch opens the first collection path, directing all the plurality of pellets into the first collection path; and if one or more pellets are identified not to meet preset conditions, the diverter switch opens the second collection path, and the control unit triggers an instantaneous high-speed air pneumatic ejection of the first airflow from the first air jet nozzle, redirecting all the plurality of pellets towards the second collection path.
In a preferred embodiment, a pellet sorting device further comprising a third air jet nozzle that provides a third airflow to the pellet flow channel. The third airflow jetted from the second end of the pellet flow channel towards the second collection path, the control unit is connected to the third air jet nozzle and the control unit controls the first airflow and the third airflow are air pneumatic ejected at high speed from the first air jet nozzle and the third air jet nozzle, respectively, directing all the plurality of pellets towards the second collection path.
A pellet flow channel of a pellet sorting device, comprising: a airflow unit comprising a first air jet nozzle and a second air jet nozzle, the first air jet nozzle and the second air jet nozzle provide a first airflow and a second airflow to the pellet flow channel. the first airflow jets from the first end of the pellet flow channel towards the second end, causing the plurality of pellets to move from the first end to the second end of the pellet flow channel. the second airflow jets towards the pellet flow channel from the second end, inducing and controlling the plurality of pellets to rolling, rotating, tumbling or maintaining momentarily stillness as it passes through the pellet flow channel.
In a preferred embodiment, the airflow unit further comprising: a third air jet nozzle provides a third airflow to the pellet flow channel. The third airflow jetted from the second end of the pellet flow channel towards a second collection path connected to the pellet flow channel.
In a preferred embodiment, the pellet flow channel is horizontal, vertical or inclined.

The effective results of this invention:

control the presence, angle, direction, flow rate, and frequency of the first airflow and second airflow, thereby inducing and controlling the plurality of pellets to undergo motion such as rolling, rotating, tumbling, or maintaining momentarily stillness. This facilitates comprehensive all directional multi-angles' images of the plurality of pellets in the pellet flow channel by the optical camera, rather than partial imaging. The optical camera can capture all directional images of all plurality of pellets in the pellet flow channel. Any pellets that meet or do not meet the preset conditions can be captured by the optical camera and sorted out by the digital image data processor.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only and thus are not limitative of the present disclosure and wherein:

FIG. 1 is a schematic diagram of a prior art;
FIG. 2 is a cross-sectional diagram of the pellet sorting device and its connection relationship;
FIG. 3 is a cross-sectional diagram of controlling the plurality of pellet entering the first collection path in FIG. 2;
FIG. 4 is a cross-sectional diagram of controlling the plurality of pellet entering the second collection path in FIG. 2; and
FIG. 5 is a block diagram of the pellet sorting device.

DETAILED DESCRIPTION

In the following detailed description, we will illustrate embodiments of the present invention with reference to the accompanying drawings and examples. The illustrations provided are intended to schematically demonstrate the basic concept of the present invention. While the components depicted in the drawings represent relevant components of the present invention, it should be noted that their number, shape, and size may vary in practical implementation.
In addition, these relative terms are for convenience of description and do not require that the present disclosure be constructed or operated in a particular orientation. In addition, terms such as "first", "second" and "third" are used herein for purposes of description and are not intended to indicate or imply relative importance or significance. In the description of the present disclosure, it should be understood that, unless specified or limited otherwise, the terms "mounted," "connected," and "coupled" and variations thereof are used broadly and encompass such as mechanical or electrical mountings, connections and couplings, also can be inner mountings, connections and couplings of two components, and further can be direct and indirect mountings, connections, and couplings, which can be understood by those skilled in the art according to the detail embodiment of the present disclosure.
Please refer to FIG. 2 and FIG. 5, the pellet sorting device includes a pellet flow channel 10, a feeding unit 15, an optical camera 18, a first collection path 21, a second collection path 23, a diverter switch 25, an airflow unit 30, and a control unit 40.
The pellet flow channel 10, enclosed and transparent with both open ends. The first end 11 of the pellet flow channel 10 serves as an inlet, while the second end 12 serves as an outlet. The pellet flow channel 10 can be horizontal, vertical, or inclined. The inclination angle and direction can be set as needed, without limitation in this invention.
The feeding unit 15 is installed at the first end 11 of the pellet flow channel 10, feeding the plurality of pellets 16 into the pellet flow channel 10 through the inlet. The plurality of pellet 16 includes, but is not limited to, plastic pellets. The feeding unit 15 can provide the plurality of pellet 16 to the pellet flow channel 10 in a continuous or intermittent manner.
The optical camera 18, including but not limited to a matrix high-speed color optical camera. The optical camera 18 captures images of all the plurality of pellet 16 in the pellet flow channel 10. The captured all directional multi-angles' images are then sent to the digital image data processor 19 for identification and analysis.
The first collection path 21, connected beneath the second end 12 of the pellet flow channel 10, is used to guide the plurality of pellet 16 that meets preset conditions (e.g., defect-free) to a first collection unit 22.
The second collection path 23, connected above the second end 12 of the pellet flow channel 10, is used to guide the plurality of pellet 16 that does not meet preset conditions (e.g., defectives) to a second collection unit 24.
The diverter switch 25 is positioned between the first collection path 21 and the second collection path 23, allowing it to open one path while closing the other. The diverter switch 25 can use any known route switching control technology, including but not limited to electronic control valves or diverter plates (as shown in the figure), without limitation in this invention.
The airflow unit 30 comprising a first air jet nozzle 31, a second air jet nozzle 32, and a third air jet nozzle 33, all connected to a compressed air pneumatic source (not shown in the figures). The first air jet nozzle 31 and the second air jet nozzle 32 provide a first airflow 35 and a second airflow 36 to the pellet flow channel 10. The first airflow 35 is directed from the first end 11 of the pellet flow channel 10 towards the second end 12, causing the plurality of pellet 16 to move from the first end 11 to the second end 12. The second airflow 36 is directed from the second end 12 of the pellet flow channel 10 towards the first end 11, controlling the presence, angle, direction, velocity, and frequency of the first airflow 35 and the second airflow 36 to disturb the pellet 16, inducing rolling, rotating, tumbling or maintaining momentarily stillness. This facilitates a comprehensive all directional multi-angles' images of the plurality of pellets rather than only particular angle of pellet imaging in the pellet flow channel 10 by the optical camera 18. The third air jet nozzle 33 provides a third airflow 37 to the pellet flow channel 10 air jetting from the second end 12 towards the second collection path 23.
The control unit 40 is connected to the first air jet nozzle 31, the second air jet nozzle 32, the third air jet nozzle 33, and the digital image data processor 19. The control unit 40 receives identification and analysis results from the digital image data processor 19. If the analysis result indicates that the plurality of pellet 16 meets the preset conditions (e.g., defect-free) the diverter switch 25 opens the first collection path 21, allowing the plurality of pellet 16 directed to the first collection path 21. If the result indicates if one or more of the plurality of pellet 16 does not meet the preset conditions (e.g., defectives) the diverter switch 25 opens the second collection path 23. The control unit 40 then controls the first air jet nozzle 31 and the third air jet nozzle 33 instantaneously air pneumatic eject the first airflow 35 and the third airflow 37 at high speed, directing the plurality of pellet 16 towards the second collection path 23.
The above is the structural layout of the pellet sorting device of the present invention. Below are the operational methods of this invention.
Please refer to FIG. 3, the feeding unit 15 supplies the plurality of pellet 16 to the pellet flow channel 10. The first air jet nozzle 31 releases the first airflow 35, the second air jet nozzle 32 releases the second airflow 36, and the third air jet nozzle 33 remains closed. Simultaneously, the diverter switch 25 opens the first collection path 21 and closes the second collection path 23, controlling the presence, angle, direction, velocity, and frequency of the first airflow 35 and the second airflow 36 to disturb the plurality of pellet 16, inducing movements such as rolling, rotating, tumbling or maintaining momentarily stillness. This allows the optical camera 18 to capture all directional multi-angles' images of the plurality of pellet 16 in the pellet flow channel 10. Any of the plurality of pellet 16, whether meeting or not meeting the preset conditions, can be captured by the optical camera 18 and identify by the digital image data processor 19.
The velocity and frequency of the first airflow 35 and the second airflow 36 can be adjusted to regulate the time for the plurality of pellet 16 to pass through the pellet flow channel 10. For example, increasing the velocity and frequency of the second airflow 36 and allowing the plurality of pellet 16 to stay in the pellet flow channel 10 for a longer period may slightly reduce sorting throughput but can enhance the sorting accuracy. On the contrary, increasing the velocity and frequency of the first airflow 35 will shorten the image processing time of the plurality of pellet 16 through the pellet flow channel 10, accelerating sorting throughput but potentially leading to a slight decrease in sorting purity performance.
If all the plurality of pellet 16 in the pellet flow channel 10 meets the preset conditions, all the plurality of pellet 16 will pass through the first collection path 21 and enters the first collection unit 22.
Please refer to FIG. 4, If one or more pellets 16 are identified from all the plurality of pellets 16 in the pellet flow channel 10 as not meeting the preset conditions (e.g., defects), the diverter switch 25 opens the second collection path 23. The control unit 40 then controls the first air jet nozzle 31 and the third air jet nozzle 33 to generate an instantaneous high-speed air pneumatic ejection of the first airflow 35 and the third airflow 37. This directs the plurality of pellet 16 towards the second collection path 23, entering the second collection unit 24.
In the above explanation, the plurality of pellet 16 that meets the preset conditions enters the first collection unit 22 through the first collection path 21, while the plurality of pellet 16 that does not meet the preset conditions enters the second collection unit 24 through the second collection path 23. Vice versa is also possible.
In the embodiment, a preferred implementation of the diverter switch 25 is described. The diverter switch 25 is a plate-shaped component with a pivot 251 is provided at an eccentric position so that the diverter switch 25 can swing. Positioned relative to the end of the pellet flow channel 10, a counterweight 252 is attached to the diverter switch 25. The weight of the counterweight 252 causes the diverter switch 25 to close the second collection path 23 and open the first collection path 21 in its default stationary state. Thus, as shown in Figure 3, if a batch of the plurality of pellet 16 in the pellet flow channel 10 all meets the preset conditions (e.g., defect-free), the tilting of the pellet flow channel 10, aided by the first airflow 35, causes all the pellet 16 to pass through the first collection path 21 and enter the first collection unit 22.
However, as show in FIG. 4, If one or more from the plurality of pellet 16 in a batch in the pellet flow channel 10 are identified as not meeting the preset conditions(e.g., defectives), the first air jet nozzle 31 generates a momentary air pneumatic release of the first airflow 35. This instantaneous air pneumatic release of the first airflow 35 not only propels the plurality of pellet 16 but also triggers the diverter switch 25 to open the second collection path 23 and close the first collection path 21. This directs the plurality of pellet 16 towards the second collection path 23, entering the second collection unit 24.
From the above description, the diverter switch 25 is controlled by the counterweight 252 and the air pneumatic release of the first airflow 35.
It will be apparent to those skilled in the art that various modifications and variations can be made to the present disclosure. It is intended that the specification and examples be considered as exemplary embodiments only, with a scope of the disclosure being indicated by the following claims and their equivalents.

Claims

A pellet sorting method, comprising:
feeding a plurality of pellets (16) into a pellet flow channel (10);

the pellet flow channel (16) is enclosed and transparent with both open ends;

supplying a first airflow (35) and a second airflow (36) to the pellet flow channel (10), the first airflow (35) jets from the first end (11) of the pellet flow channel (10) to the second end (12), causing the plurality of pellets (16) to move from the first end (11) to the second end (12) of the pellet flow channel (10);

the second airflow (36) jets from the second end (12) of the pellet flow channel (10) towards the first end (11), inducing and controlling the plurality of pellets (16) by the first airflow (35) and second airflow (36) to make them roll, rotate, tumble, or maintain momentarily stillness as they pass through the pellet flow channel (10);

using an optical camera (18) to comprehensively capture all directional multi-angles' images of the plurality of pellets (16) from the pellet flow channel (10) and sending these captured images to an digital image data processor (19) for identification and analysis;

if the identification and analysis result determines that all the plurality of pellets (16) meet a preset conditions, all the plurality of pellets (16) directed to a first collection path (21); and

if the identification and analysis result determines that one or more of the plurality of pellets (16) do not meet the preset conditions, the first airflow (35) is instantaneously air pneumatic ejected at high speed, directing all the plurality of pellets (16) in the pellet flow channel (10) towards a second collection path (23).
The pellet sorting method according to claim 1, further comprising a third airflow (37), which jets from the second end (12) of the pellet flow channel (10) towards the second collection path (23), in coordination with the high-speed air pneumatic ejection of the first airflow (35) to direct all the plurality of pellets (16) towards the second collection path (23).
The pellet sorting method according to claim 2, wherein the first airflow (35) jets from the first end (11) to the second end (12) of the pellet flow channel (10) in a lower section of the pellet flow channel (10), while the second airflow (36) jets from the second end (12) to the first end (11) of the pellet flow channel (10) in an upper section of the pellet flow channel (10).
A pellet sorting device, comprising:
a pellet flow channel (10) which is enclosed and transparent with both open ends;

a feeding unit (15) feeds a plurality of pellets (16) from a first end (11) of the pellet flow channel (10) to the pellet flow channel (10);

an airflow unit (30) comprising a first air jet nozzle (31) and a second air jet nozzle (32), which provide a first airflow (35) and a second airflow (36) to the pellet flow channel (10), respectively, the first airflow (35) jets from the first end (11) of the pellet flow channel (10) towards the second end (12), causing the plurality of pellets (16) to move from the first end (11) to the second end (12) of the pellet flow channel (10), the second airflow (36) jets towards the pellet flow channel (10) from the second end (12), inducing and controlling the plurality of pellets (16) to roll, rotate, tumble, or maintain momentarily stillness as it passes through the pellet flow channel (10);

a first collection path (21) connected to the second end (12) of the pellet flow channel (10);

a second collection path (23) connected to the second end (12) of the pellet flow channel (10);

a diverter switch (25) controlling the opening of either the first collection path (21) or the second collection path (23);

an optical camera (18) for comprehensive captured all directional multi-angles' images of the plurality of pellets (16) in the pellet flow channel (10), sending these images to an digital image data processor (19) for identification and analysis;

if all the plurality of pellets (16) are identified to meet preset conditions, the diverter switch (25) opens the first collection path (21), directing all the plurality of pellets (16) into the first collection path (21); and

if one or more from the plurality of pellets (16) are identified not to meet preset conditions, the diverter switch (25) opens the second collection path (23), and the control unit (40) triggers an instantaneous high-speed air pneumatic ejection of the first airflow (35) from the first air jet nozzle (31), redirecting all the plurality of pellets (16) towards the second collection path (23).
The pellet sorting device according to claim 4, further comprising a third air jet nozzle (33), wherein the third air jet nozzle (33) provides a third airflow (37) to the pellet flow channel (10), and the third airflow (37) jets from the second end (12) of the pellet flow channel (10) towards the second collection path (23), the control unit (40) is connected to the third air jet nozzle (23), the control unit (40) controls the first airflow (35) and the third airflow (37) are air pneumatic ejected at high speed from the first air jet nozzle (31) and the third air jet nozzle (33), respectively, directing all the plurality of pellets (16) towards the second collection path (23).
A pellet flow channel of a pellet sorting device, comprising:
a airflow unit (30) comprises a first air jet nozzle (31) and a second air jet nozzle (32), the first air jet nozzle (31) and the second air jet nozzle (32) provide a first airflow (35) and a second airflow (36) to the pellet flow channel (10);

the first airflow (35) jets from the first end (11) of the pellet flow channel (10) towards the second end (12), causing the plurality of pellets (16) to move from the first end (11) to the second end (12) of the pellet flow channel (10);

the second airflow (36) jets towards the pellet flow channel (10) from the second end (12), inducing and controlling the plurality of pellets (16) to rolling, rotating, tumbling or maintaining momentarily stillness as it passes through the pellet flow channel (10).
The pellet flow channel of the pellet sorting device according to claim 6, further comprising:
a third air jet nozzle (33) provides a third airflow (37) to the pellet flow channel (10), the third airflow (37) is air pneumatic sprayed from the second end (12) of the pellet flow channel (10) towards a second collection path (23) connected to the pellet flow channel (10).
The pellet flow channel of the pellet sorting device according to claim 6, wherein the pellet flow channel (10) is horizontal.
The pellet flow channel of the pellet sorting device according to claim 6, wherein the pellet flow channel (10) is vertical.
The pellet flow channel of the pellet sorting device according to claim 6, wherein the pellet flow channel (10) is inclined.