WO2022170262A1 - Sorting of plastics - Google Patents
Sorting of plastics Download PDFInfo
- Publication number
- WO2022170262A1 WO2022170262A1 PCT/US2022/015665 US2022015665W WO2022170262A1 WO 2022170262 A1 WO2022170262 A1 WO 2022170262A1 US 2022015665 W US2022015665 W US 2022015665W WO 2022170262 A1 WO2022170262 A1 WO 2022170262A1
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- WO
- WIPO (PCT)
- Prior art keywords
- plastic
- pieces
- type
- spectroscopy
- piece
- Prior art date
Links
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07C—POSTAL SORTING; SORTING INDIVIDUAL ARTICLES, OR BULK MATERIAL FIT TO BE SORTED PIECE-MEAL, e.g. BY PICKING
- B07C5/00—Sorting according to a characteristic or feature of the articles or material being sorted, e.g. by control effected by devices which detect or measure such characteristic or feature; Sorting by manually actuated devices, e.g. switches
- B07C5/34—Sorting according to other particular properties
- B07C5/342—Sorting according to other particular properties according to optical properties, e.g. colour
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
- B29B17/02—Separating plastics from other materials
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N15/00—Investigating characteristics of particles; Investigating permeability, pore-volume or surface-area of porous materials
- G01N15/02—Investigating particle size or size distribution
- G01N15/0205—Investigating particle size or size distribution by optical means
- G01N15/0227—Investigating particle size or size distribution by optical means using imaging; using holography
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N15/00—Investigating characteristics of particles; Investigating permeability, pore-volume or surface-area of porous materials
- G01N15/10—Investigating individual particles
- G01N15/14—Optical investigation techniques, e.g. flow cytometry
- G01N15/1429—Signal processing
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N15/00—Investigating characteristics of particles; Investigating permeability, pore-volume or surface-area of porous materials
- G01N15/10—Investigating individual particles
- G01N15/14—Optical investigation techniques, e.g. flow cytometry
- G01N15/1429—Signal processing
- G01N15/1433—Signal processing using image recognition
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N15/00—Investigating characteristics of particles; Investigating permeability, pore-volume or surface-area of porous materials
- G01N15/10—Investigating individual particles
- G01N15/14—Optical investigation techniques, e.g. flow cytometry
- G01N15/1434—Optical arrangements
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N15/00—Investigating characteristics of particles; Investigating permeability, pore-volume or surface-area of porous materials
- G01N15/10—Investigating individual particles
- G01N15/14—Optical investigation techniques, e.g. flow cytometry
- G01N15/1456—Optical investigation techniques, e.g. flow cytometry without spatial resolution of the texture or inner structure of the particle, e.g. processing of pulse signals
- G01N15/1459—Optical investigation techniques, e.g. flow cytometry without spatial resolution of the texture or inner structure of the particle, e.g. processing of pulse signals the analysis being performed on a sample stream
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N15/00—Investigating characteristics of particles; Investigating permeability, pore-volume or surface-area of porous materials
- G01N15/10—Investigating individual particles
- G01N15/14—Optical investigation techniques, e.g. flow cytometry
- G01N15/1468—Optical investigation techniques, e.g. flow cytometry with spatial resolution of the texture or inner structure of the particle
- G01N15/147—Optical investigation techniques, e.g. flow cytometry with spatial resolution of the texture or inner structure of the particle the analysis being performed on a sample stream
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/17—Systems in which incident light is modified in accordance with the properties of the material investigated
- G01N21/25—Colour; Spectral properties, i.e. comparison of effect of material on the light at two or more different wavelengths or wavelength bands
- G01N21/31—Investigating relative effect of material at wavelengths characteristic of specific elements or molecules, e.g. atomic absorption spectrometry
- G01N21/35—Investigating relative effect of material at wavelengths characteristic of specific elements or molecules, e.g. atomic absorption spectrometry using infrared light
- G01N21/3563—Investigating relative effect of material at wavelengths characteristic of specific elements or molecules, e.g. atomic absorption spectrometry using infrared light for analysing solids; Preparation of samples therefor
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Definitions
- Patent Application Serial No. 16/852,514 which is a divisional application of U.S. Patent Application Serial No. 16/358,374 (issued as U.S. Patent No. 10,625,304), which is a continuation-in-part application of U.S. Patent Application Serial No. 15/963,755 (issued as U.S. Patent No. 10,710,119).
- the present disclosure relates in general to the sorting of solid waste, and in particular, to the sorting of pieces of plastics from municipal or industrial solid waste.
- Recycling is the process of collecting and processing materials (e.g., from waste streams) that would otherwise be thrown away as trash, and turning them into new products, or at least enabling a more appropriate disposal. Recycling has benefits for communities and for the environment, since it reduces the amount of waste sent to landfills, conserves natural resources such as timber, water, and minerals, increases economic security by tapping a domestic source of materials, prevents pollution by reducing the need to collect new raw materials, and saves energy. After collection, recyclables may be sent to a material recovery facility (“MRF”) to be sorted, cleaned, and processed into materials that can be used in manufacturing.
- MRF material recovery facility
- MRFs are either unable to discriminate between many materials, which limits the sorted materials to lower quality and lower value markets, or too slow, labor intensive, and inefficient, which limits the amount of material that can be economically recycled or recovered.
- MSW Municipal Solid Waste
- the EPA has reported that in 2017, 267.8 million tons of MSW were generated. 35.37 million tons, or 13.2% of the total weight of that MSW was composed of plastics. Of those 35.37 million tons of plastic, 2.96 million tons (8.4%) of plastic were recycled, 5.59 million tons (15.8%) were combusted with energy recovery, and 26.82 million tons (75.8%) were landfilled. Clearly there is a need for more recycling of plastics.
- Plastic recycling is the reprocessing of plastic waste into new and useful products. Recycling is necessary because almost all plastic is non-biodegradable and thus builds-up in the environment. Presently, almost all recycling is performed by remelting and reforming used plastic into new items; so-called mechanical recycling. This can cause polymer degradation at a chemical level, and also requires that plastic waste be sorted by both color and polymer type before being reprocessed, which is complicated and expensive. Failures in this can lead to materials with inconsistent properties, which is unappealing to industry. In an alternative approach known as feedstock recycling, plastic waste is converted back into its starting chemicals, which can then be reprocessed back into fresh plastic. This offers the hope of greater recycling but suffers from higher energy and capital costs. Plastic waste can also be burnt in place of fossil fuels as part of energy recovery.
- Plastic packaging and products that are made from a single material (e.g., polyethylene terephthalate (“PET”), high density polyethylene (“HDPE”), and polypropylene (“PP”)) can be more easily recycled.
- PET polyethylene terephthalate
- HDPE high density polyethylene
- PP polypropylene
- Plastics that are sometimes or almost never recyclable include polyvinyl chloride (“PVC”), low density polyethylene (“LDPE”), linear low-density polyethylene (“LLDPE”), and polystyrene (“PS”). Additionally, plastic can only be recycled a limited number of times.
- PVC polyvinyl chloride
- LDPE low density polyethylene
- LLDPE linear low-density polyethylene
- PS polystyrene
- NIR spectroscopy can identify #1 type plastics that are clear and light blue PET and #2 HDPE, while rejecting #1 colored PET, #3 PVC, #4 LDPE, #5 PP, #6 PS, and #7 Other plastics such as multilayered polymers, composite polymers, acrylic, and nylon. Furthermore, NIR spectroscopy cannot accurately identify black or strongly colored plastics, as well as composite materials like plastic-coated paper and multilayered packaging (made of polymer multilayer films), which can give misleading readings. Most black plastic is pigmented using carbon. Black plastics are widely used in the automotive industry, electronics, food packages, plastic bags, etc.
- black plastics also absorb the near-infrared part of the spectrum, which has the unfortunate side-effect of making it invisible to NIR spectroscopy.
- the “stealthy” black plastic thus passes undetected into the “miscellaneous” bin at the end of the conveyor, which is burned for energy or dumped to a landfill.
- the quality of the plastic is reduced each time it is recycled, so that the material cannot be indefinitely recycled and eventually becomes waste.
- the recycling of PET bottles into fleece or other fibers is a common example, and accounts for the majority of PET recycling.
- the reduction in polymer quality can be offset by mixing recycled plastic with virgin material or compatibilized plastics when making a new product.
- thermoset polymers do not melt, technologies have been developed for their mechanical recycling. This usually involves breaking the material down to a crumb, which can then be mixed with some sort of binding agent to form a new composite material.
- feedstock or tertiary, recycling (also called chemical recycling)
- polymers are reduced to their chemical building-blocks (monomers), which can then be polymerized back into fresh plastics.
- Thermal depolymerization and chemical depolymerization are two types of feedstock recycling.
- Energy recovery also called energy recycling or quaternary recycling, involves burning plastic waste in place of fossil fuels for energy production.
- a process has been developed in which certain kinds of plastic can be used as a carbon source (in place of coke) in the recycling of scrap steel.
- Ground plastic may be used as a construction aggregate or filler material in certain applications.
- Plastic waste may be simply burnt as refuse-derived fuel (“RDF”) in a waste-to-energy process, or it may be first chemically converted to a synthetic fuel.
- RDF refuse-derived fuel
- PVC must be excluded or compensated for by installing dichlorination technologies, as it generates large amounts of hydrogen chloride (HC1) when burnt, which can corrode equipment and cause undesirable chlorination of the fuel products.
- HC1 hydrogen chloride
- FIG. 1 illustrates a schematic of a sorting system configured in accordance with certain embodiments of the present disclosure.
- FIG. 2 illustrates an exemplary representation of a control set of material pieces used during a training stage in a machine learning system.
- FIG. 3 illustrates a flowchart diagram configured in accordance with certain embodiments of the present disclosure.
- FIG. 4 illustrates a simplified schematic diagram configured in accordance with certain embodiments of the present disclosure.
- FIGS. 5 and 6 illustrate examples of chemical signatures.
- FIG. 7 illustrates a flowchart diagram configured in accordance with certain embodiments of the present disclosure.
- FIG. 8 illustrates a flowchart diagram configured in accordance with certain embodiments of the present disclosure.
- FIG. 9 illustrates a block diagram of a data processing system configured in accordance with certain embodiments of the present disclosure. Detailed Description
- materials may include any item or object, including but not limited to, metals (ferrous and nonferrous), metal alloys, plastics (including, but not limited to any of the plastics disclosed herein, known in the industry, or newly created in the future), rubber, foam, glass (including, but not limited to borosilicate or soda lime glass, and various colored glass), ceramics, paper, cardboard, Teflon, PE, bundled wires, insulation covered wires, rare earth elements, leaves, wood, plants, parts of plants, textiles, bio-waste, packaging, electronic waste, batteries and accumulators, end-of-life vehicles, mining, construction, and demolition waste, crop wastes, forest residues, purpose-grown grasses, woody energy crops, microalgae, urban food waste, food waste, hazardous chemical and biomedical wastes, construction debris, farm wastes, biogenic items, non-biogenic items, objects with a specific carbon content, any other objects that may be found within municipal solid waste, and any other objects, items, or materials disclosed here
- a “material” may include any item or object composed of a chemical element, a compound or mixture of chemical elements, or a compound or mixture of a compound or mixture of chemical elements, wherein the complexity of a compound or mixture may range from being simple to complex.
- element means a chemical element of the periodic table of elements, including elements that may be discovered after the filing date of this application.
- the terms “scrap,” “scrap pieces,” “materials,” and “material pieces” may be used interchangeably.
- a “polymer” is a substance or material composed of very large molecules, or macromolecules, composed of many repeating subunits.
- a polymer may be a natural polymer found in nature or a synthetic polymer.
- Multilayer polymer films are composed of two or more different compositions and may possess a thickness of up to about 7.5 x x 10 -4 m.
- the layers are at least partially contiguous and preferably, but optionally, coextensive.
- plastic As used herein, the terms “plastic,” “plastic piece,” and “piece of plastic material” (all of which may be used interchangeably) refer to any object that includes or is composed of a polymer composition of one or more polymers and/or multilayer polymer films.
- the term “chemical signature” refers to a unique pattern (e.g., fingerprint spectrum), as would be produced by one or more analytical instruments, indicating the presence of one or more specific elements or molecules (including polymers) in a sample.
- the elements or molecules may be organic and/or inorganic.
- Such analytical instruments include any of the sensor systems disclosed herein.
- one or more sensor systems disclosed herein may be configured to produce a chemical signature of a material piece (e.g., a plastic piece).
- a “fraction” refers to any specified combination of organic and/or inorganic elements or molecules, polymer types, plastic types, polymer compositions, chemical signatures of plastics, physical characteristics of the plastic piece (e.g., color, transparency, strength, melting point, density, shape, size, manufacturing type, uniformity, reaction to stimuli, etc.), etc., including any and all of the various classifications and types of plastics disclosed herein.
- Non-limiting examples of fractions are one or more different types of plastic pieces that contain: LDPE plus a relatively high percentage of aluminum; LDPE and PP plus a relatively low percentage of iron; PP plus zinc; combinations of PE, PET, and HDPE; any type of red-colored LDPE plastic pieces; any combination of plastic pieces excluding PVC; blackcolored plastic pieces; combinations of #3— #7 type plastics that contain a specified combination of organic and inorganic molecules; combinations of one or more different types of multi-layer polymer films; combinations of specified plastics that do not contain a specified contaminant or additive; any types of plastics with a melting point greater than a specified threshold; any thermoset plastic of a plurality of specified types; specified plastics that do not contain chlorine; combinations of plastics having similar densities; combinations of plastics having similar polarities; plastic bottles without attached caps or vice versa.
- Catalytic pyrolysis involves the degradation of the polymeric materials by heating them in the absence of oxygen and in the presence of a catalyst.
- predetermined refers to something that has been established or decided in advance.
- Spectral imaging is imaging that uses multiple bands across the electromagnetic spectrum. While an ordinary camera captures light across three wavelength bands in the visible spectrum, red, green, and blue (RGB), spectral imaging encompasses a wide variety of techniques that include but go beyond RGB. Spectral imaging may use the infrared, visible, ultraviolet, and/or x-ray spectrums, or some combination of the above. Spectral data, or spectral image data, is a digital data representation of a spectral image. Spectral imaging may include the acquisition of spectral data in visible and non-visible bands simultaneously, illumination from outside the visible range, or the use of optical filters to capture a specific spectral range. It is also possible to capture hundreds of wavelength bands for each pixel in a spectral image.
- image data packet refers to a packet of digital data pertaining to a captured spectral image of an individual material piece.
- the terms “identify” and “classify,” the terms “identification” and “classification,” and any derivatives of the foregoing, may be utilized interchangeably.
- to “classify” a piece of material is to determine (i.e., identify) a type or class of materials to which the piece of material belongs.
- a sensor system may be configured to collect and analyze any type of information for classifying materials, which classifications can be utilized within a sorting system to selectively sort material pieces as a function of a set of one or more physical and/or chemical characteristics (e.g., which may be user- defined), including but not limited to, color, texture, hue, shape, brightness, weight, density, composition, size, uniformity, manufacturing type, chemical signature, predetermined fraction, radioactive signature, transmissivity to light, sound, or other signals, and reaction to stimuli such as various fields, including emitted and/or reflected electromagnetic radiation (“EM”) of the material pieces.
- physical and/or chemical characteristics e.g., which may be user- defined
- manufacturing type refers to the type of manufacturing process by which the material piece was manufactured, such as a metal part having been formed by a wrought process, having been cast (including, but not limited to, expendable mold casting, permanent mold casting, and powder metallurgy), having been forged, a material removal process, etc.
- the types or classes (i.e., classification) of materials may be user-definable and not limited to any known classification of materials.
- the granularity of the types or classes may range from very coarse to very fine.
- the types or classes may include plastics, ceramics, glasses, metals, and other materials, where the granularity of such types or classes is relatively coarse; different metals and metal alloys such as, for example, zinc, copper, brass, chrome plate, and aluminum, where the granularity of such types or classes is finer; or between specific types of plastic, where the granularity of such types or classes is relatively fine.
- the types or classes may be configured to distinguish between materials of significantly different compositions such as, for example, different types of plastics (e.g., between any of the #1 through #7 types of plastics), or to distinguish between materials of almost identical composition such as, for example, different subclasses of plastics that may fall within a particular plastic type. It should be appreciated that the methods and systems discussed herein may be applied to accurately identify/classify pieces of material for which the composition is completely unknown before being classified.
- Embodiments of the present disclosure advance plastic sorting capabilities by a fusion of multiple sensor technologies and a machine learning system.
- Limitations of sensor-based sorter technologies arise from the use of a single sensor, as each sensor is only able to detect a narrow range of signals.
- the most common sorter sensor types are eddy current, visible camera, x-ray transmission, near infrared, and x-ray fluorescence (“XRF”), which are summarized in the following table.
- Plastic pieces in MSW can be composed of one or more organic polymers, one or more inorganic elements, and come in many different colors, shapes, and sizes. Examples of these plastics include potato chip bags, squeezable juice boxes, select drink containers, and electronics electromagnetic sensitive packaging.
- Embodiments of the present disclosure create novel fractions from this waste stream with a sensor-based technology that is able to achieve sorting of these different types of plastics into unique classifications that can account for their organic polymer composition and/or their inorganic elemental composition.
- a conversion chemist for example, who is highly concerned with relative composition of polymers and inorganic elements would then be able to select one or more novel fractions that enable the creation of a particular product from the recycled plastics sorted into such fractions.
- sorting systems configured in accordance with embodiments of the present disclosure can produce fractions beyond what is possible with existing state-of-the-art sorting technologies.
- certain embodiments of the present disclosure may be configured to classify and/or sort a predetermined fraction from bales of #3— #7 type plastics to create new products (e.g., by recycling methods) and/or fuels.
- exemplary end uses for such fractions may include, but are not limited to, gases (e.g., C1-C4), fuels (e.g., gasoline, diesel), and vacuum gas oils.
- gases e.g., C1-C4
- fuels e.g., gasoline, diesel
- vacuum gas oils e.g., vacuum gas oils
- Embodiments of the present disclosure may be configured to classify pieces of plastic materials according to various different predetermined fractions or combinations of characteristics or types, which are disclosed hereinafter and elsewhere within this disclosure.
- plastics According to their characteristics, there are three types of classifications regarding plastics according to their chemical structure, their polarity, and their applications.
- plastics can be divided into thermoplastics, thermosets, and elastomers.
- polarity With regard to polarity, the presence of atoms of a different nature causes electrons to move towards the most electronegative atom in covalent bonds, thus resulting in a dipole.
- Polymers containing these extremely electronegative atoms such as CI, O, N, F, etc., will be polar compounds, which has an effect on the properties of the material. If the polarity is increased, the mechanical resistance, hardness, rigidity, heat resistance, water and moisture absorption, and chemical resistance, as well as permeability to polar compounds such as water vapor and adhesivity and adherence to metals is also increased. At the same time, the increase in polarity reduces the thermal expansion, the electrical insulation capacity, the tendency to accumulate electrostatic charges and the permeability to polar molecules (Oz, N2). In this way, it is possible to distinguish between different families such as polyolefins, polyesters, acetals, halogenated polymers, and others.
- thermoplastic materials There are four types of plastics within this third classification:
- Standard plastics or commodities plastics manufactured and used in large quantities due to their price and good characteristics in many ways.
- Some examples are polyethylene (“PE”), polypropylene (“PP”), polystyrene (“PS”), polyvinyl chloride (“PVC”), or the copolymer acrylonitrile butadiene styrene (“ABS”).
- Engineering plastics used when good structural, transparency, self-lubrication, and thermal properties are needed.
- Some examples are polyamide (“PA”), polyacetal (“POM”), polycarbonate (“PC”), polyethylene terephthalate (“PET”), polyphenylene ether (“PPE”), and polybutylene terephthalate (“PBT”).
- PMMA polymethyl methacrylate
- Teflon polytetrafluoroethylene
- High-performance plastics mostly thermoplastic with high heat resistance. In other words, they have good mechanical resistance to high temperatures, particularly up to 150°C.
- Polyimide (“PI”), polysulfone (“PSU”), polyethersulfone (“PES”), polyarylsulfone (“PAS”), polyphenylene sulfide (“PPS”), and liquid crystal polymers (“LCP”) are high-performance plastics.
- Polymer type #1 refers to polyethylene terephthalate (“PET”)
- #2 refers to high-density polyethylene (“HDPE”)
- #3 refers to polyvinylchloride (“PVC”)
- #4 refers to low-density polyethylene (“LDPE”)
- #5 refers to polypropylene (“PP”)
- #6 refers to polystyrene (“PS”)
- #7 refers to other polymers not in polymer types #1— #6 (e.g., acrylic, polycarbonate (“PC”), polyactic fibers, polylactide, nylon, fiberglass, ABS).
- the EU maintains a similar nine-code list, which also includes ABS and polyamides.
- PET plastic is used to make many common household items such as beverage bottles, medicine jars, rope, clothing, and carpet fiber.
- HDPE plastic is often use to make containers for milk, motor oil, shampoos and conditioners, soap bottles, detergent, and bleaches.
- PVC is used for all kinds of pipes and tiles and most commonly found in plumbing pipes.
- LDPE products include cling-film, sandwich bags, squeezable bottles, and plastic grocery bags.
- PP is used to make lunchboxes, margarine containers, yogurt pots, syrup bottles, prescription bottles, and plastic bottle caps.
- Polystyrene items include disposable coffee cups, plastic food boxes, plastic cutlery, and packaging foam.
- Polycarbonate is used in baby bottles, compact discs, and medical storage containers. Therefore, in accordance with embodiments of the present disclosure, a vision system implemented with a machine learning system may be trained to discern and sort between these different types of plastics based on the type of product they have been made into.
- Plastic pieces may be classified depending upon the types of additives they may contain. Additives are compounds blended into plastics to enhance performance and include stabilizers, fillers, and dyes. Clear plastics hold the highest value as they may yet be dyed, while black or strongly colored plastic is much less valuable, as their inclusion can give discolored products. Thus, plastic may need to be sorted by both polymer type and color to give a material suitable for recycling. Plastics may also be classified and sorted based on density. Certain polymers have similar density ranges (for example, PP and PE, or PET, PS, and PVC). If a plastic piece contains a high percentage of fillers, this may affect its density.
- Plastic waste can also be broadly divided into two categories: industrial scrap (sometimes referred to as postindustrial resin) and post-consumer waste.
- Plastic pieces may also be classified/sorted due to how they may be recycled.
- plastics may be reprocessed at anywhere between 150-320°C, depending on the polymer type, which may cause unwanted chemical reactions that result in polymer degradation. This can reduce the physical properties and overall quality of the plastic and can produce volatile, low-molecular weight compounds, which may impart undesirable taste or odor, as well as causing thermal discoloration. Therefore, embodiments of the present disclosure may be configured to classify and sort plastic pieces so that such unwanted chemical reactions are avoided. Additives present within the plastic can accelerate this degradation. For instance, oxo-biodegradable additives, intended to improve the biodegradability of plastic, can increase the degree of thermal degradation. Similarly, flame retardants can have unwanted effects. Therefore, embodiments of the present disclosure may be configured to classify and sort plastic pieces so that plastic pieces with certain ones of such additives are discarded.
- the quality of the product may also strongly depend on how well the plastic was sorted. Many polymers are immiscible with one another when molten and will phase separate (like oil and water) during reprocessing. Products made from such blends contain many boundaries between the different polymer types, and cohesion across these boundaries is weak, leading to poor mechanical properties. Therefore, embodiments of the present disclosure may be configured to classify and sort plastic pieces so that certain immiscible plastic pieces are not sorted together into the same group.
- the systems and methods described herein receive a heterogeneous mixture of a plurality of material pieces (e.g., any combination of the various plastics disclosed herein), wherein at least one material piece within this heterogeneous mixture includes a composition of elements (e.g., chemical signature) different from one or more other material pieces and/or at least one material piece within this heterogeneous mixture is distinguishable (e.g., visually discernible characteristics or features, different chemical signatures, etc.) from other material pieces, and the systems and methods are configured to identify/classify/sort this material piece into a group separate from such other material pieces.
- Embodiments of the present disclosure may be utilized to sort any types or classes of materials, or fractions as defined herein.
- Embodiments of the present disclosure will be described herein as sorting material pieces into such separate groups by physically depositing (e.g., diverting or ejecting) the material pieces into separate receptacles or bins as a function of user-defined groupings (e.g., material type classifications or fractions).
- material pieces may be sorted into separate bins in order to separate material pieces having physical characteristics that are distinguishable from the physical characteristics of other material pieces (e.g., visually discernible characteristics or features, different chemical signatures, etc.).
- FIG. 1 illustrates an example of a system 100 configured in accordance with various embodiments of the present disclosure.
- a conveyor system 103 may be implemented to convey one or more streams of individual material pieces 101 through the system 100 so that each of the individual material pieces 101 can be tracked, classified, and sorted into predetermined desired groups.
- Such a conveyor system 103 may be implemented with one or more conveyor belts on which the material pieces 101 travel, typically at a predetermined constant speed.
- certain embodiments of the present disclosure may be implemented with other types of conveyor systems, including a system in which the material pieces free fall past the various components of the system 100 (or any other type of vertical sorter), or a vibrating conveyor system.
- the conveyor system 103 may also be referred to as the conveyor belt 103.
- some or all of the acts of conveying, stimulating, detecting, classifying, and sorting may be performed automatically, i.e., without human intervention.
- one or more sources of stimuli, one or more emissions detectors, a classification module, a sorting apparatus, and/or other system components may be configured to perform these and other operations automatically.
- FIG. 1 illustrates a single stream of material pieces 101 on a conveyor system 103
- embodiments of the present disclosure may be implemented in which a plurality of such streams of material pieces are passing by the various components of the system 100 in parallel with each other.
- the material pieces may be distributed into two or more parallel singulated streams travelling on a single conveyor belt, or a set of parallel conveyor belts.
- certain embodiments of the present disclosure are capable of simultaneously tracking, classifying, and sorting a plurality of such parallel travelling streams of material pieces.
- incorporation or use of a singulator is not required. Instead, the conveyor system (e.g., the conveyor system 103) may simply convey a mass of material pieces, which have been deposited onto the conveyor system 103 in a random manner.
- some sort of suitable feeder mechanism e.g., another conveyor system or hopper 102
- the conveyor system 103 conveys the material pieces 101 past various components within the system 100.
- an optional tumbler/ vibrator/singulator 106 may be utilized to separate the individual material pieces from a collection of material pieces.
- the conveyor system 103 is operated to travel at a predetermined speed by a conveyor system motor 104. This predetermined speed may be programmable and/or adjustable by the operator in any well-known manner.
- Monitoring of the predetermined speed of the conveyor system 103 may alternatively be performed with a position detector 105.
- control of the conveyor system motor 104 and/or the position detector 105 may be performed by an automation control system 108.
- Such an automation control system 108 may be operated under the control of a computer system 107 and/or the functions for performing the automation control may be implemented in software within the computer system 107.
- the conveyor system 103 may be a conventional endless belt conveyor employing a conventional drive motor 104 suitable to move the belt conveyor at the predetermined speeds.
- the position detector 105 which may be a conventional encoder, may be operatively coupled to the conveyor system 103 and the automation control system 108 to provide information corresponding to the movement (e.g., speed) of the conveyor belt.
- the automation control system 108 is able to track the location of each of the material pieces 101 while they travel along the conveyor system 103.
- certain embodiments of the present disclosure may utilize a vision, or optical recognition, system 110 and/or a material piece tracking device 111 as a means to track each of the material pieces 101 as they travel on the conveyor system 103.
- the vision system 110 may utilize one or more still or live action cameras 109 to note the position (i.e., location and timing) of each of the material pieces 101 on the moving conveyor system 103.
- the vision system 110 may be further, or alternatively, configured to perform certain types of identification (e.g., classification) of all or a portion of the material pieces 101, as will be further described herein.
- such a vision system 110 may be utilized to capture or acquire information about each of the material pieces 101.
- the vision system 110 may be configured (e.g., with a machine learning system) to capture or collect any type of information from the material pieces that can be utilized within the system 100 to classify and/or selectively sort the material pieces 101 as a function of a set of one or more characteristics (e.g., physical and/or chemical and/or radioactive, etc.) as described herein.
- the vision system 110 may be configured to capture visual images of each of the material pieces 101 (including one-dimensional, two-dimensional, three-dimensional, or holographic imaging), for example, by using an optical sensor as utilized in typical digital cameras and video equipment.
- image data e.g., formatted as image data packets.
- image data may represent images captured within optical wavelengths of light (i.e., the wavelengths of light that are observable by the typical human eye).
- alternative embodiments of the present disclosure may utilize sensor systems that are configured to capture an image of a material made up of wavelengths of light outside of the visual wavelengths of the human eye.
- the system 100 may be implemented with one or more sensor systems 120, which may be utilized solely or in combination with the vision system 110 to classify/identify material pieces 101.
- a sensor system 120 may be configured with any type of sensor technology for determining chemical signatures of plastic pieces and/or classifying plastic pieces for sorting, including sensor systems utilizing irradiated or reflected electromagnetic radiation (e.g., utilizing infrared (“IR”), Fourier Transform IR (“FTIR”), Forward-looking Infrared (“FLIR”), Very Near Infrared (“VNIR”), Near Infrared (“NIR”), Short Wavelength Infrared (“SWIR”), Long Wavelength Infrared (“LWIR”), Medium Wavelength Infrared (“MWIR” or “MIR”), X-Ray Transmission (“XRT”), Gamma Ray, Ultraviolet (“UV”), X-Ray Fluorescence (“XRF”), Laser Induced Breakdown Spectroscopy (“LIBS”), Raman
- IR infrared
- XRF can be used within embodiments of the present disclosure to identify inorganic materials within a plastic piece (e.g., for inclusion within a chemical signature).
- the following sensor systems may also be used within certain embodiments of the present disclosure for determining the chemical signatures of plastic pieces and/or classifying plastic pieces for sorting.
- infrared spectroscopy may be utilized to obtain a chemical signature specific of each plastic piece that provides information about the base polymer of any plastic material, as well as other components present in the material (mineral fillers, copolymers, polymer blends, etc.).
- DSC Differential Scanning Calorimetry
- TGA Thermogravimetric analysis
- Capillary and rotational rheometry can determine the rheological properties of polymeric materials by measuring their creep and deformation resistance.
- Optical and scanning electron microscopy can provide information about the structure of the materials analyzed regarding the number and thickness of layers in multilayer materials (e.g., multilayer polymer films), dispersion size of pigment or filler particles in the polymeric matrix, coating defects, interphase morphology between components, etc.
- FIG. 1 is illustrated with a combination of a vision system 110 and one or more sensor systems 120, embodiments of the present disclosure may be implemented with any combination of sensor systems utilizing any of the sensor technologies disclosed herein, or any other sensor technologies currently available or developed in the future.
- FIG. 1 is illustrated with a combination of a vision system 110 and one or more sensor systems 120, embodiments of the present disclosure may be implemented with any combination of sensor systems utilizing any of the sensor technologies disclosed herein, or any other sensor technologies currently available or developed in the future. Though FIG.
- embodiments of the present disclosure are illustrated as including one or more sensor systems 120, implementation of such sensor system(s) is optional within certain embodiments of the present disclosure.
- a combination of both the vision system 110 and one or more sensor systems 120 may be used to classify the material pieces 101.
- any combination of one or more of the different sensor technologies disclosed herein may be used to classify the material pieces 101 without utilization of a vision system 110.
- embodiments of the present disclosure may include any combinations of one or more sensor systems and/or vision systems in which the outputs of such sensor/vision systems are processed within a machine learning system (as further disclosed herein) in order to classify/identify materials from a heterogeneous mixture of materials, which can then be sorted from each other.
- a vision system 110 and/or sensor system(s) may be configured to identify which of the material pieces 101 are not of the kind to be sorted by the system 100 (e.g., plastic pieces containing a specific contaminant, additive, or undesirable physical feature (e.g., an attached container cap formed of a different type of plastic than the container)), and send a signal to reject such material pieces.
- the identified material pieces 101 may be diverted/ejected utilizing one of the mechanisms as described hereinafter for physically diverting sorted material pieces into individual bins.
- the material piece tracking device 111 and accompanying control system 112 may be utilized and configured to measure the sizes and/or shapes of each of the material pieces 101 as they pass within proximity of the material piece tracking device 111, along with the position (i.e., location and timing) of each of the material pieces 101 on the moving conveyor system 103.
- An exemplary operation of such a material piece tracking device 111 and control system 112 is further described in U.S. Patent No. 10,207,296.
- the vision system 110 may be utilized to track the position (i.e., location and timing) of each of the material pieces 101 as they are transported by the conveyor system 103.
- certain embodiments of the present disclosure may be implemented without a material piece tracking device (e.g., the material piece tracking device 111) to track the material pieces.
- the sensor system(s) 120 may be configured to assist the vision system 110 to identify the chemical composition, relative chemical compositions, and/or manufacturing types of each of the material pieces 101 as they pass within proximity of the sensor system(s) 120.
- the sensor system(s) 120 may include an energy emitting source 121, which may be powered by a power supply 122, for example, in order to stimulate a response from each of the material pieces 101.
- the source 121 may include an in-line x-ray fluorescence (“IL-XRF”) tube, such as further described within U.S. Patent No. 10,207,296.
- Such an IL-XRF tube may include a separate x- ray source each dedicated for one or more streams (e.g., singulated) of conveyed material pieces.
- the one or more detectors 124 may be implemented as XRF detectors to detect fluoresced x-rays from material pieces 101 within each of the singulated streams. Examples of such XRF detectors are further described within U.S. Patent No. 10,207,296.
- the sensor system 120 may emit an appropriate sensing signal towards the material piece 101.
- One or more detectors 124 may be positioned and configured to sense/detect one or more characteristics from the material piece 101 in a form appropriate for the type of utilized sensor technology.
- the one or more detectors 124 and the associated detector electronics 125 capture these received sensed characteristics to perform signal processing thereon and produce digitized information representing the sensed characteristics (e.g., spectral data), which is then analyzed in accordance with certain embodiments of the present disclosure, which may be used in order to assist the vision system 110 to classify each of the material pieces 101.
- This classification which may be performed within the computer system 107, may then be utilized by the automation control system 108 to activate one of the N (N>1) sorting devices 126... 129 of a sorting apparatus for sorting (e.g., diverting/ejecting) the material pieces 101 into one or more N (N>1) sorting bins 136... 139 according to the determined classifications.
- N (N>1) sorting devices 126... 129 and four sorting bins 136... 139 associated with the sorting devices are illustrated in FIG. 1 as merely a non-limiting example.
- Existing sorters for plastics are designed to sort materials in a binary fashion, where air nozzles at the end of the conveyor eject an identified class of plastics into one of two bins. For example, if four classes of plastics needed to be separated, the entire stream would need to be conveyed through such a binary sorter four different times, which takes four times as long as trying to remove one single object in the stream.
- the system 100 allows for multiple classifications of plastics to be sorted in one pass.
- the sorting apparatus may include any well-known mechanisms for redirecting selected material pieces 101 towards a desired location, including, but not limited to, diverting the material pieces 101 from the conveyor belt system into a plurality of sorting bins.
- a sorting apparatus may utilize air jets, with each of the air jets assigned to one or more of the classifications.
- one of the air jets e.g., 127) receives a signal from the automation control system 108, that air jet emits a stream of air that causes a material piece 101 to be diverted/ejected from the conveyor system 103 into a sorting bin (e.g., 137) corresponding to that air jet.
- Other mechanisms may be used to divert/eject the material pieces, such as robotically removing the material pieces from the conveyor belt, pushing the material pieces from the conveyor belt (e.g., with paint brush type plungers), causing an opening (e.g., a trap door) in the conveyor system 103 from which a material piece may drop, or using air jets to divert the material pieces into separate bins as they fall from the edge of the conveyor belt.
- robotically removing the material pieces from the conveyor belt e.g., pushing the material pieces from the conveyor belt (e.g., with paint brush type plungers), causing an opening (e.g., a trap door) in the conveyor system 103 from which a material piece may drop, or using air jets to divert the material pieces into separate bins as they fall from the edge of the conveyor belt.
- a pusher device may refer to any form of device which may be activated to dynamically displace an object on or from a conveyor system/device, employing pneumatic, mechanical, or other means to do so, such as any appropriate type of mechanical pushing mechanism (e.g., an ACME screw drive), pneumatic pushing mechanism, or air jet pushing mechanism.
- Some embodiments may include multiple pusher devices located at different locations and/or with different diversion path orientations along the path of the conveyor system. In various different implementations, these sorting systems describe herein may determine which pusher device to activate (if any) depending on classifications of material pieces performed by the machine learning system.
- the determination of which pusher device to activate may be based on the detected presence and/or characteristics of other objects that may also be within the diversion path of a pusher device concurrently with a target item.
- the disclosed sorting systems can recognize when multiple objects are not well singulated, and dynamically select from a plurality of pusher devices which should be activated based on which pusher device provides the best diversion path for potentially separating objects within close proximity.
- objects identified as target objects may represent material that should be diverted off of the conveyor system.
- objects identified as target objects represent material that should be allowed to remain on the conveyor system so that non-target materials are instead diverted.
- the system 100 may also include a receptacle or bin 140 that receives material pieces 101 not diverted/ejected from the conveyor system 103 into any of the aforementioned sorting bins 136... 139.
- a material piece 101 may not be diverted/ejected from the conveyor system 103 into one of the N sorting bins 136... 139 when the classification of the material piece 101 is not determined (or simply because the sorting devices failed to adequately divert/eject a piece).
- the bin 140 may serve as a default receptacle into which unclassified material pieces are dumped.
- the bin 140 may be used to receive one or more classifications of material pieces that have deliberately not been assigned to any of the N sorting bins 136... 139. These such material pieces may then be further sorted in accordance with other characteristics and/or by another sorting system.
- multiple classifications may be mapped to a single sorting device and associated sorting bin.
- it may be desired by the user to sort certain classifications of materials into the same sorting bin e.g., different plastic types that fall within a fraction.
- the same sorting device may be activated to sort these into the same sorting bin.
- Such combination sorting may be applied to produce any desired combination of sorted material pieces.
- the mapping of classifications may be programmed by the user (e.g., using the sorting algorithm (e.g., see FIG. 7) operated by the computer system 107) to produce such desired combinations. Additionally, the classifications of material pieces are user-definable, and not limited to any particular known classifications of material pieces (e.g., fractions as disclosed herein).
- the conveyor system 103 may include a circular conveyor (not shown) so that unclassified material pieces are returned to the beginning of the system 100 and run through the system 100 again. Moreover, because the system 100 is able to specifically track each material piece 101 as it travels on the conveyor system 103, some sort of sorting device (e.g., the sorting device 129) may be implemented to direct/eject a material piece 101 that the system 100 has failed to classify after a predetermined number of cycles through the system 100 (or the material piece 101 is collected in bin 140).
- some sort of sorting device e.g., the sorting device 129 may be implemented to direct/eject a material piece 101 that the system 100 has failed to classify after a predetermined number of cycles through the system 100 (or the material piece 101 is collected in bin 140).
- the conveyor system 103 may be divided into multiple belts configured in series such as, for example, two belts, where a first belt conveys the material pieces past the vision system 110, and a second belt conveys certain sorted material pieces past an implemented sensor system 120 for a second sort. Moreover, such a second conveyor belt may be at a lower height than the first conveyor belt, such that the material pieces fall from the first belt onto the second belt.
- the emitting source 121 may be located above the detection area (i.e., above the conveyor system 103); however, certain embodiments of the present disclosure may locate the emitting source 121 and/or detectors 124 in other positions that still produce acceptable sensed/detected physical characteristics.
- the systems and methods described herein may be applied to classify and/or sort individual material pieces having any of a variety of sizes and shapes. Even though the systems and methods described herein are described primarily in relation to sorting individual material pieces, the systems and methods described herein are not limited thereto. Such systems and methods may be used to stimulate and/or detect emissions from a plurality of materials concurrently. For example, as opposed to a singulated stream of materials being conveyed along one or more conveyor belts in series, multiple singulated streams may be conveyed in parallel. Each stream may be a on a same belt or on different belts arranged in parallel. Further, pieces may be randomly distributed on (e.g., across and along) one or more conveyor belts.
- the systems and methods described herein may be used to stimulate, and/or detect emissions from, a plurality of material pieces at the same time.
- a plurality of material pieces may be treated as a single piece as opposed to each material piece being considered individually.
- the plurality of pieces of material may be classified and sorted (e.g., diverted/ejected from the conveyor system) together.
- certain embodiments of the present disclosure may implement one or more vision systems (e.g., vision system 110) in order to identify, track, and/or classify material pieces.
- vision system(s) may operate alone to identify and/or classify and sort material pieces, or may operate in combination with one or more sensor systems (e.g., sensor system(s) 120) to identify and/or classify and sort material pieces.
- sensor system(s) 120 may be omitted from the system 100 (or simply deactivated).
- the information may then be sent to a computer system (e.g., computer system 107) to be processed by a machine learning system in order to identify and/or classify each of the material pieces.
- a computer system e.g., computer system 107
- Such a machine learning system may implement any well-known machine learning system, including one that implements a neural network (e.g., artificial neural network, deep neural network, convolutional neural network, recurrent neural network, autoencoders, reinforcement learning, etc.), fuzzy logic, artificial intelligence (“Al”), deep learning algorithms, deep structured learning hierarchical learning algorithms, support vector machine (“SVM”) (e.g., linear SVM, nonlinear SVM, SVM regression, etc.), decision tree learning (e.g., classification and regression tree (“CART”), ensemble methods (e.g., ensemble learning, Random Forests, Bagging and Pasting, Patches and Subspaces, Boosting, Stacking, etc.), dimensionality reduction (e.g., Projection, Manifold Learning, Principal Components Analysis, etc.) and/or deep machine learning algorithms, such as those described in and publicly available at the deeplearning.net website (including all software, publications, and hyperlinks to available software referenced within this website), which is hereby incorporated by reference herein.
- Non-limiting examples of publicly available machine learning software and libraries that could be utilized within embodiments of the present disclosure include Python, OpenCV, Inception, Theano, Torch, PyTorch, Pylearn2, Numpy, Blocks, TensorFlow, MXNet, Caffe, Lasagne, Keras, Chainer, Matlab Deep Learning, CNTK, MatConvNet (a MATLAB toolbox implementing convolutional neural networks for computer vision applications), DeepLearnToolbox (a Matlab toolbox for Deep Learning (from Rasmus Berg Palm)), BigDL, Cuda-Convnet (a fast C++/CUDA implementation of convolutional (or more generally, feed-forward) neural networks), Deep Belief Networks, RNNLM, RNNLIB-RNNLIB, matrbm, deep learning 4j, Eblearn.lsh, deepmat, MShadow, Matplotlib, SciPy, CXXNET, Nengo-Nengo, Eblearn, cudamat, Gnumpy, 3-way factor
- machine learning may be performed in two stages. For example, first, training occurs, which may be performed offline in that the system 100 is not being utilized to perform actual classifying/sorting of material pieces (e.g., see FIGS. 3- 4).
- the system 100 may be utilized to train the machine learning system in that homogenous sets (also referred to herein as control samples) of material pieces (i.e., having the same types or classes of materials, or falling within the same predetermined fraction) are passed through the system 100 (e.g., by a conveyor system 103); and all such material pieces may not be sorted, but may be collected in a common bin (e.g., bin 140).
- homogenous sets also referred to herein as control samples
- material pieces i.e., having the same types or classes of materials, or falling within the same predetermined fraction
- the training may be performed at another location remote from the system 100, including using some other mechanism for collecting sensed information (characteristics) of control sets of material pieces.
- algorithms within the machine learning system extract features from the captured information (e.g., using image processing techniques well known in the art).
- Non-limiting examples of training algorithms include, but are not limited to, linear regression, gradient descent, feed forward, polynomial regression, learning curves, regularized learning models, and logistic regression.
- Such a knowledge base may include one or more libraries, wherein each library includes parameters (e.g., neural network parameters) for utilization by the machine learning system in classifying material pieces.
- each library includes parameters (e.g., neural network parameters) for utilization by the machine learning system in classifying material pieces.
- one particular library may include parameters configured by the training stage to recognize and classify a particular type or class of material, or one or more material that fall with a predetermined fraction.
- such libraries may be inputted into the machine learning system and then the user of the system 100 may be able to adjust certain ones of the parameters in order to adjust an operation of the system 100 (for example, adjusting the threshold effectiveness of how well the machine learning system recognizes a particular material piece from a heterogeneous mixture of materials).
- a plurality of material pieces 201 of one or more specific types, classifications, or fractions of material(s), which are the control samples may be delivered past the vision system and/or one or more sensor system(s) (e.g., by a conveyor system 203) so that the algorithms within the machine learning system detect, extract, and learn what features represent such a type or class of material.
- each of the material pieces 201 may be an individual plastic piece of a specific type, class, or predetermined fraction, which are passed through such a training stage so that the algorithms within the machine learning system “learn” (are trained) how to detect, recognize, and classify such plastic pieces accordingly.
- a vision system e.g., the vision system 110
- This creates a library of parameters particular to one or more specific types, classes, or fractions of plastic materials.
- the same process may be performed with respect to different types, classes, or fractions of plastic pieces, creating a library of parameters particular to that type, class, or fraction, and so on.
- any number of exemplary plastic pieces of that type, class, or fraction of plastic may be passed through the system.
- the algorithms within the machine learning system may use N classifiers, each of which test for one of N different material types, classes, or fractions.
- the machine learning system may be “taught” (trained) to detect any type, class, or fraction of material, including any of the types, classes, or fractions materials found within MSW, or any other material disclosed herein.
- the libraries for the different material classifications are then implemented into a material classifying/sorting system (e.g., system 100) to be used for identifying and/or classifying material pieces from a heterogeneous mixture of material pieces (e.g., as contained within MSW), and then possibly sorting such classified material pieces if sorting is to be performed.
- data captured by a vision or sensor system with respect to a particular material piece may be processed as an array of data values (within a data processing system (e.g., the data processing system 3400 of FIG. 9) implementing (configured with) a machine learning system).
- the data may be spectral data captured by a digital camera or other type of sensor system with respect to a particular material piece and processed as an array of data values (e.g., image data packets).
- Each data value may be represented by a single number, or as a series of numbers representing values.
- neuron weight parameters e.g., with a neural network
- the resulting number output by the neuron can be treated much as the values were, with this output multiplied by subsequent neuron weight values, a bias optionally added, and once again fed into a neuron nonlinearity.
- Each such iteration of the process is known as a “layer” of the neural network.
- the final outputs of the final layer may be interpreted as probabilities that a material is present or absent in the captured data pertaining to the material piece. Examples of such a process are described in detail in both of the previously noted “ImageNet Classification with Deep Convolutional Networks” and “Gradient-Based Learning Applied to Document Recognition” references.
- the final set of neurons’ output is trained to represent the likelihood a material piece is associated with the captured data.
- the likelihood that a material piece is associated with the captured data is over a user-specified threshold, then it is determined that the material piece is indeed associated with the captured data.
- a sensor system may utilize optical spectrometric techniques using multi- or hyper- spectral cameras to provide a signal that may indicate the presence or absence of a type, class, or fraction of material by examining the spectral emissions (i.e., spectral imaging) of the material.
- Spectral images of a material piece may also be used in a template-matching algorithm, wherein a database of spectral images is compared against an acquired spectral image to find the presence or absence of certain types of materials from that database.
- a histogram of the captured spectral image may also be compared against a database of histograms.
- a bag of words model may be used with a feature extraction technique, such as scale-invariant feature transform (“SIFT”), to compare extracted features between a captured spectral image and those in a database.
- SIFT scale-invariant feature transform
- certain embodiments of the present disclosure provide for the identification/classification of one or more different types, classes, or fractions of materials in order to determine which material pieces should be diverted from a conveyor system in defined groups.
- machine learning techniques are utilized to train (i.e., configure) a neural network to identify a variety of one or more different types, classes, or fractions of materials.
- Spectral images, or other types of sensed information are captured of materials (e.g., traveling on a conveyor system), and based on the identification/classification of such materials, the systems described herein can decide which material piece should be allowed to remain on the conveyor system, and which should be diverted/removed from the conveyor system (for example, either into a collection bin, or diverted onto another conveyor system).
- a machine learning system for an existing installation may be dynamically reconfigured to identify/classify characteristics of a new type, class, or fraction of materials by replacing a current set of neural network parameters with a new set of neural network parameters.
- the detected/captured features/characteristics (e.g., spectral images) of the material pieces may not be necessarily simply particularly identifiable or discernible physical characteristics; they can be abstract formulations that can only be expressed mathematically, or not mathematically at all; nevertheless, the machine learning system may be configured to parse the spectral data to look for patterns that allow the control samples to be classified during the training stage. Furthermore, the machine learning system may take subsections of captured information (e.g., spectral images) of a material piece and attempt to find correlations between the pre-defined classifications.
- training of the machine learning system may be performed utilizing a labeling/ annotation technique whereby as data/information of material pieces are captured by a vision/ sensor system, a user inputs a label or annotation that identifies each material piece, which is then used to create the library for use by the machine learning system when classifying material pieces within a heterogenous mixture of material pieces.
- embodiments of the present disclosure combine or fuse multiple sensor technologies (e.g., any combination of visual (“VIS”), XRF, NIR, and MWIR) in a manner that uniquely identifies various types, classes, or fractions of plastics so that they can be sorted out by their organic and inorganic chemical composition.
- sensor technologies e.g., any combination of visual (“VIS”), XRF, NIR, and MWIR
- VIS visual
- XRF XRF
- NIR nuclear magnetic resonance
- certain embodiments of the present disclosure may implement a system (e.g., the system 100) with a fewer number of sensor systems (and resultant lower capital and operating costs) to increase economic viability but yet be capable of sufficiently sorting materials.
- FIG. 4 illustrates a simplified schematic diagram of a system (e.g., the system 100) whereby material pieces (e.g., plastic pieces) 401 are conveyed by a conveyor system 403 past the sensor system(s) that capture spectral data from each material piece 401.
- the sensor system(s) are a camera 410 (e.g., the vision system 110) capturing visible image data of each material piece 401, an XRF system 411, an NIR system 412, and a MWIR system 413. Note, however, that any other sensor systems disclosed herein may be utilized in any combination.
- chemical signatures of materials are determined in the process block 301 with one or more sensor systems.
- the sensed/detected/captured signal from the sensor system(s) are combined (e.g., in a multidimensional data array) for each material piece to create a chemical signature.
- the XRF sensor system is capable of determining the presence of inorganic elements or molecules within the plastic pieces
- a combination of one or more other sensor systems, such as the NIR and MWIR is capable of determining the presence of organic elements or molecules within the plastic pieces.
- a visible image of each material piece is captured.
- FIGS. 5 and 6 illustrate non-limiting exemplary representations of chemical signatures and associated image data for two different types of plastic materials — a potato chip bag and electronics packaging.
- different types or classes of plastic pieces will possess different (unique) chemical signatures, which are utilized within embodiments of the present disclosure to produce fractions and/or classifications (which may be user defined) for plastic waste.
- control groups of specific types or classes of plastic pieces may be run through the system illustrated in FIG. 4 in order to train a machine learning system to associate a specific chemical signature with a specific type or class of plastic piece.
- images captured from multiple potato chip bags may be processed through to train the machine learning system.
- the process block 304 may involve separating the plastic pieces into one or more fractions.
- fractions There are many ways to create these fractions.
- One method is to create a first tier based on a primary element and then secondary and even tertiary tiers based on minor elements.
- fractions could be determined first by polymer type and then branching into inorganic elements such as aluminum and zinc.
- Other exemplary fractions could then be created for blends of polymers and then branching out into their inorganic elemental composition.
- There are also computational methods to perform this type of clustering to determine fractions such as principal component analysis, K-means clustering and unsupervised and semi-semi supervised learning. Fractions are further defined herein.
- the plastic pieces pertaining to the fractions may be sorted (e.g., manually) to create a control group for each fraction. Because each fraction was measured with the sensor system(s), each control group contains chemical information about the pieces.
- a vision system e.g., the vision system 110
- the chemical data in the plastics is transferred to visual features, which the machine learning system can learn to classify.
- the system 100 is used to perform the classification based on the visual images, it is also separating the plastics by chemical composition. This method works when the two objects look different and have different chemical compositions. When the two objects look the same or very similar and have different chemical compositions, two or more sensor systems may be used to perform the classification (e.g., VIS plus XRF, etc.).
- the process 300 may be utilized to train a machine learning system implemented within a sorting system so that it is configured to sort a heterogeneous mixture of different plastic pieces to produce at least one fraction that contains plastic pieces of one or more different types or classes. For example, if the machine learning system has been trained to identify any plastic piece that contains a specified combination of organic and/or inorganic elements or molecules, then when the sorting is completed, that sorted out fraction may contain plastic pieces that are not all identical (i.e., a plurality of plastic chip bags that pertain to different brands of chips, since each plastic chip bag is composed of the organic and/or inorganic elements or molecules that are defined by the predetermined fraction).
- FIG. 7 illustrates a flowchart diagram depicting exemplary embodiments of a process 3500 of classifying/sorting material pieces utilizing a vision system and/or one or more sensor systems in accordance with certain embodiments of the present disclosure.
- the process 3500 may be performed to classify a heterogeneous mixture of plastic pieces into any combination of predetermined types, classes, and/or fractions.
- the process 3500 may be configured to operate within any of the embodiments of the present disclosure described herein, including the system 100 of FIG. 1. Operation of the process 3500 may be performed by hardware and/or software, including within a computer system (e.g., computer system 3400 of FIG.
- the material pieces may be deposited onto a conveyor system.
- the location on the conveyor system of each material piece is detected for tracking of each material piece as it travels through the system 100. This may be performed by the vision system 110 (for example, by distinguishing a material piece from the underlying conveyor system material while in communication with a conveyor system position detector (e.g., the position detector 105)).
- a material tracking device 111 can be used to track the pieces.
- any system that can create a light source including, but not limited to, visual light, UV, and IR
- a detector that can be used to locate the pieces.
- sensed information/characteristics of the material piece is captured/acquired.
- a vision system may perform pre-processing of the captured information, which may be utilized to detect (extract) information of each of the material pieces (e.g., from the background (e.g., the conveyor belt); in other words, the preprocessing may be utilized to identify the difference between the material piece and the background).
- Well- known image processing techniques such as dilation, thresholding, and contouring may be utilized to identify the material piece as being distinct from the background.
- segmentation may be performed.
- the captured information may include information pertaining to one or more material pieces. Additionally, a particular material piece may be located on a seam of the conveyor belt when its image is captured.
- a first step is to apply a high contrast of the image; in this fashion, background pixels are reduced to substantially all black pixels, and at least some of the pixels pertaining to the material piece are brightened to substantially all white pixels.
- the image pixels of the material piece that are white are then dilated to cover the entire size of the material piece.
- the location of the material piece is a high contrast image of all white pixels on a black background.
- a contouring algorithm can be utilized to detect boundaries of the material piece. The boundary information is saved, and the boundary locations are then transferred to the original image. Segmentation is then performed on the original image on an area greater than the boundary that was earlier defined. In this fashion, the material piece is identified and separated from the background.
- the material pieces may be conveyed along the conveyor system within proximity of a material piece tracking device and/or a sensor system in order to track each of the material pieces and/or determine a size and/or shape of the material pieces, which may be useful if an XRF system or some other spectroscopy sensor is also implemented within the sorting system.
- post processing may be performed. Post processing may involve resizing the captured information/data to prepare it for use in the machine learning system. This may also include modifying certain properties (e.g., enhancing image contrast, changing the image background, or applying filters) in a manner that will yield an enhancement to the capability of the machine learning system to classify the material pieces.
- the data may be resized.
- Data resizing may be desired under certain circumstances to match the data input requirements for certain machine learning systems, such as neural networks.
- neural networks may require much smaller image sizes (e.g., 225 x 255 pixels or 299 x 299 pixels) than the sizes of the images captured by typical digital cameras.
- image sizes e.g., 225 x 255 pixels or 299 x 299 pixels
- the smaller the input data size the less processing time is needed to perform the classification.
- smaller data sizes can ultimately increase the throughput of the system 100 and increase its value.
- each material piece is identified/classified based on the sensed/detected features.
- the process block 3510 may be configured with a neural network employing one or more machine learning algorithms, which compare the extracted features with those stored in a previously generated knowledge base (e.g., generated during a training stage), and assigns the classification with the highest match to each of the material pieces based on such a comparison.
- the algorithms of the machine learning system may process the captured information/data in a hierarchical manner by using automatically trained filters. The filter responses are then successfully combined in the next levels of the algorithms until a probability is obtained in the final step.
- these probabilities may be used for each of the N classifications to decide into which of the N sorting receptacles the respective material pieces should be sorted.
- each of the N classifications may be assigned to one sorting receptacle, and the material piece under consideration is sorted into that receptacle that corresponds to the classification returning the highest probability larger than a predefined threshold.
- predefined thresholds may be preset by the user.
- a particular material piece may be sorted into an outlier receptacle (e.g., sorting receptacle 140) if none of the probabilities is larger than the predetermined threshold.
- a sorting device corresponding to the classification, or classifications, of the material piece is activated.
- the material piece has moved from the proximity of the vision system and/or sensor system(s) to a location downstream on the conveyor system (e.g., at the rate of conveying of a conveyor system).
- the activation of the sorting device is timed such that as the material piece passes the sorting device mapped to the classification of the material piece, the sorting device is activated, and the material piece is diverted/ejected from the conveyor system into its associated sorting receptacle.
- the activation of a sorting device may be timed by a respective position detector that detects when a material piece is passing before the sorting device and sends a signal to enable the activation of the sorting device.
- the sorting receptacle corresponding to the sorting device that was activated receives the diverted/ejected material piece.
- FIG. 8 illustrates a flowchart diagram depicting exemplary embodiments of a process 800 of sorting material pieces in accordance with certain embodiments of the present disclosure.
- the process 800 may be configured to operate within any of the embodiments of the present disclosure described herein, including the system 100 of FIG. 1.
- the process 800 may be configured to operate in conjunction with the process 3500.
- the process blocks 803 and 804 may be incorporated in the process 3500 (e.g., operating in series or in parallel with the process blocks 3503-3510) in order to combine the efforts of a vision system 110 that is implemented in conjunction with a machine learning system with a sensor system (e.g., the sensor system 120) that is not implemented in conjunction with a machine learning system in order to classify and/or sort material pieces.
- a vision system 110 that is implemented in conjunction with a machine learning system with a sensor system (e.g., the sensor system 120) that is not implemented in conjunction with a machine learning system in order to classify and/or sort material pieces.
- a sensor system e.g., the sensor system 120
- Operation of the process 800 may be performed by hardware and/or software, including within a computer system (e.g., computer system 3400 of FIG. 9) controlling the system (e.g., the computer system 107 of FIG. 1).
- the material pieces may be deposited onto a conveyor system.
- the material pieces may be conveyed along the conveyor system within proximity of a material piece tracking device and/or an optical imaging system in order to track each material pieces and/or determine a size and/or shape of the material pieces.
- the material piece when a material piece has traveled in proximity of the sensor system, the material piece may be interrogated, or stimulated, with EM energy (waves) or some other type of stimulus appropriate for the particular type of sensor technology utilized by the sensor system.
- EM energy waves
- the process block 804 physical characteristics of the material piece are sensed/detected and captured by the sensor system.
- the type of material is identified/classified based (at least in part) on the captured characteristics, which may be combined with the classification by the machine learning system in conjunction with the vision system 110.
- a sorting device corresponding to the classification, or classifications, of the material piece is activated. Between the time at which the material piece was sensed and the time at which the sorting device is activated, the material piece has moved from the proximity of the sensor system to a location downstream on the conveyor system, at the rate of conveying of the conveyor system.
- the activation of the sorting device is timed such that as the material piece passes the sorting device mapped to the classification of the material piece, the sorting device is activated, and the material piece is diverted/ejected from the conveyor system into its associated sorting receptacle.
- the activation of a sorting device may be timed by a respective position detector that detects when a material piece is passing before the sorting device and sends a signal to enable the activation of the sorting device.
- the sorting receptacle corresponding to the sorting device that was activated receives the diverted/ejected material piece.
- a plurality of at least a portion of the system 100 may be linked together in succession in order to perform multiple iterations or layers of sorting.
- the conveyor system may be implemented with a single conveyor belt, or multiple conveyor belts, conveying the material pieces past a first vision system (and, in accordance with certain embodiments, a sensor system) configured for sorting material pieces of a first set of a heterogeneous mixture of materials by a sorter (e.g., the first automation control system 108 and associated one or more sorting devices 126.. . 129) into a first set of one or more receptacles (e.g., sorting bins 136...
- a sorter e.g., the first automation control system 108 and associated one or more sorting devices 126.. . 129
- Such successions of systems 100 can contain any number of such systems linked together in such a manner.
- each successive system may be configured to sort out a different classified or type of material than the previous system(s).
- different types, classes, or fractions of materials may be classified by different types of sensors each for use with a machine learning system, and combined to classify material pieces in a stream of scrap or waste.
- data e.g., spectral data
- machine learning systems to perform classifications of material pieces.
- multiple sensor systems can be mounted onto a single conveyor system, with each sensor system utilizing a different machine learning system.
- multiple sensor systems can be mounted onto different conveyor systems, with each sensor system utilizing a different machine learning system.
- Certain embodiments of the present disclosure may be configured to produce a mass of materials having a content of less than a predetermined weight or volume percentage of a certain element or material after sorting.
- any combination of different types of sensor systems may be utilized to identify/classify and possibly sort materials as disclosed herein.
- each imaging or spectroscopy sensor as disclosed herein may be used to generate data from information/characteristics sensed of material pieces in order to be processed by a machine learning system specific for that sensor system.
- any sensor system can be used without processing by a machine learning system, or with processing by a machine learning system, or a combination of both.
- different types, classes, and/or fractions of materials may be classified by different types of sensor systems each for use with a machine learning system, and combined to classify material pieces in a waste stream.
- FIG. 9 a block diagram illustrating a data processing (“computer”) system 3400 is depicted in which aspects of embodiments of the disclosure may be implemented.
- the computer system 107, the automation control system 108, aspects of the sensor system(s) 120, and/or the vision system 110 may be configured similarly as the computer system 3400.
- the computer system 3400 may employ a local bus 3405 (e.g., a peripheral component interconnect (“PCI”) local bus architecture). Any suitable bus architecture may be utilized such as Accelerated Graphics Port (“AGP”) and Industry Standard Architecture (“ISA”), among others.
- AGP Accelerated Graphics Port
- ISA Industry Standard Architecture
- One or more processors 3415, volatile memory 3420, and non-volatile memory 3435 may be connected to the local bus 3405 (e.g., through a PCI Bridge (not shown)).
- An integrated memory controller and cache memory may be coupled to the one or more processors 3415.
- the one or more processors 3415 may include one or more central processor units and/or one or more graphics processor units 3401 and/or one or more tensor processing units. Additional connections to the local bus 3405 may be made through direct component interconnection or through addin boards.
- a communication (e.g., network (LAN)) adapter 3425, an I/O (e.g., small computer system interface (“SCSI”) host bus) adapter 3430, and expansion bus interface (not shown) may be connected to the local bus 3405 by direct component connection.
- An audio adapter (not shown), a graphics adapter (not shown), and display adapter 3416 (coupled to a display 3440) may be connected to the local bus 3405 (e.g., by add-in boards inserted into expansion slots).
- the user interface adapter 3412 may provide a connection for a keyboard 3413 and a mouse 3414, modem (not shown), and additional memory (not shown).
- the I/O adapter 3430 may provide a connection for a hard disk drive 3431, a tape drive 3432, and a CD-ROM drive (not shown).
- An operating system may be run on the one or more processors 3415 and used to coordinate and provide control of various components within the computer system 3400.
- the operating system may be a commercially available operating system.
- An object-oriented programming system e.g., Java, Python, etc.
- Java, Python, etc. may run in conjunction with the operating system and provide calls to the operating system from programs or programs (e.g., Java, Python, etc.) executing on the system 3400.
- Instructions for the operating system, the object-oriented operating system, and programs may be located on non-volatile memory 3435 storage devices, such as a hard disk drive 3431, and may be loaded into volatile memory 3420 for execution by the processor 3415.
- FIG. 9 may vary depending on the implementation.
- Other internal hardware or peripheral devices such as flash ROM (or equivalent nonvolatile memory) or optical disk drives and the like, may be used in addition to or in place of the hardware depicted in FIG. 9.
- any of the processes of the present disclosure may be applied to a multiprocessor computer system, or performed by a plurality of such systems 3400. For example, training of a machine learning system may be performed by a first computer system 3400, while operation of the system 100 for sorting may be performed by a second computer system 3400.
- the computer system 3400 may be a stand-alone system configured to be bootable without relying on some type of network communication interface, whether or not the computer system 3400 includes some type of network communication interface.
- the computer system 3400 may be an embedded controller, which is configured with ROM and/or flash ROM providing non-volatile memory storing operating system files or user-generated data.
- FIG. 9 The depicted example in FIG. 9 and above-described examples are not meant to imply architectural limitations. Further, a computer program form of aspects of the present disclosure may reside on any computer readable storage medium (i.e., floppy disk, compact disk, hard disk, tape, ROM, RAM, etc.) used by a computer system.
- any computer readable storage medium i.e., floppy disk, compact disk, hard disk, tape, ROM, RAM, etc.
- embodiments of the present disclosure may be implemented to perform the various functions described for identifying, tracking, classifying, and/or sorting material pieces.
- Such functionalities may be implemented within hardware and/or software, such as within one or more data processing systems (e.g., the data processing system 3400 of FIG. 9), such as the previously noted computer system 107, the vision system 110, aspects of the sensor system(s) 120, and/or the automation control system 108. Nevertheless, the functionalities described herein are not to be limited for implementation into any particular hardware/software platform.
- aspects of the present disclosure may be embodied as a system, process, method, and/or computer program product. Accordingly, various aspects of the present disclosure may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.), or embodiments combining software and hardware aspects, which may generally be referred to herein as a “circuit,” “circuitry,” “module,” or “system.” Furthermore, aspects of the present disclosure may take the form of a computer program product embodied in one or more computer readable storage medium(s) having computer readable program code embodied thereon. (However, any combination of one or more computer readable medium(s) may be utilized. The computer readable medium may be a computer readable signal medium or a computer readable storage medium.)
- a computer readable storage medium may be, for example, but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, biologic, atomic, or semiconductor system, apparatus, controller, or device, or any suitable combination of the foregoing, wherein the computer readable storage medium is not a transitory signal per se. More specific examples (a non-exhaustive list) of the computer readable storage medium may include the following: an electrical connection having one or more wires, a portable computer diskette, a hard disk, a random access memory (“RAM”) (e.g., RAM 3420 of FIG. 9), a read-only memory (“ROM”) (e.g., ROM 3435 of FIG.
- RAM random access memory
- ROM read-only memory
- a computer readable storage medium may be any tangible medium that can contain or store a program for use by or in connection with an instruction execution system, apparatus, controller, or device.
- Program code embodied on a computer readable signal medium may be transmitted using any appropriate medium, including but not limited to wireless, wire line, optical fiber cable, RF, etc., or any suitable combination of the foregoing.
- a computer readable signal medium may include a propagated data signal with computer readable program code embodied therein, for example, in baseband or as part of a carrier wave. Such a propagated signal may take any of a variety of forms, including, but not limited to, electro-magnetic, optical, or any suitable combination thereof.
- a computer readable signal medium may be any computer readable medium that is not a computer readable storage medium and that can communicate, propagate, or transport a program for use by or in connection with an instruction execution system, apparatus, controller, or device.
- each block in the flowcharts or block diagrams may represent a module, segment, or portion of code, which includes one or more executable program instructions for implementing the specified logical function(s).
- the functions noted in the blocks may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved.
- a flow-charted technique may be described in a series of sequential actions.
- the sequence of the actions, and the party performing the actions may be freely changed without departing from the scope of the teachings.
- Actions may be added, deleted, or altered in several ways.
- the actions may be re-ordered or looped.
- processes, methods, algorithms, or the like may be described in a sequential order, such processes, methods, algorithms, or any combination thereof may be operable to be performed in alternative orders.
- some actions within a process, method, or algorithm may be performed simultaneously during at least a point in time (e.g., actions performed in parallel), can also be performed in whole, in part, or any combination thereof.
- Modules implemented in software for execution by various types of processors may, for instance, include one or more physical or logical blocks of computer instructions, which may, for instance, be organized as an object, procedure, or function. Nevertheless, the executables of an identified module need not be physically located together, but may include disparate instructions stored in different locations which, when joined logically together, include the module and achieve the stated purpose for the module. Indeed, a module of executable code may be a single instruction, or many instructions, and may even be distributed over several different code segments, among different programs, and across several memory devices.
- operational data e.g., material classification libraries described herein
- modules may be identified and illustrated herein within modules, and may be embodied in any suitable form and organized within any suitable type of data structure.
- the operational data may be collected as a single data set, or may be distributed over different locations including over different storage devices.
- the data may provide electronic signals on a system or network.
- program instructions may be provided to one or more processors and/or controller(s) of a general purpose computer, special purpose computer, or other programmable data processing apparatus (e.g., controller) to produce a machine, such that the instructions, which execute via the processor(s) (e.g., GPU 3401, CPU 3415) of the computer or other programmable data processing apparatus, create circuitry or means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
- processors e.g., GPU 3401, CPU 3415
- each block of the block diagrams and/or flowchart illustrations, and combinations of blocks in the block diagrams and/or flowchart illustrations can be implemented by special purpose hardware -based systems (e.g., which may include one or more graphics processing units (e.g., GPU 3401)) that perform the specified functions or acts, or combinations of special purpose hardware and computer instructions.
- a module may be implemented as a hardware circuit including custom VLSI circuits or gate arrays, off-the-shelf semiconductors such as logic chips, transistors, controllers, or other discrete components.
- a module may also be implemented in programmable hardware devices such as field programmable gate arrays, programmable array logic, programmable logic devices, or the like.
- Computer program code i.e., instructions, for carrying out operations for aspects of the present disclosure may be written in any combination of one or more programming languages, including an object- oriented programming language such as Java, Smalltalk, Python, C++, or the like, conventional procedural programming languages, such as the “C” programming language or similar programming languages, or any of the machine learning software disclosed herein.
- the program code may execute entirely on the user’s computer system, partly on the user’s computer system, as a stand-alone software package, partly on the user’s computer system (e.g., the computer system utilized for sorting) and partly on a remote computer system (e.g., the computer system utilized to train the sensor system), or entirely on the remote computer system or server.
- the remote computer system may be connected to the user’s computer system through any type of network, including a local area network (“LAN”) or a wide area network (“WAN”), or the connection may be made to an external computer system (for example, through the Internet using an Internet Service Provider).
- LAN local area network
- WAN wide area network
- Internet Service Provider an Internet Service Provider
- program instructions may also be stored in a computer readable storage medium that can direct a computer system, other programmable data processing apparatus, controller, or other devices to function in a particular manner, such that the instructions stored in the computer readable medium produce an article of manufacture including instructions which implement the function/act specified in the flowchart and/or block diagram block or blocks.
- the program instructions may also be loaded onto a computer, other programmable data processing apparatus, controller, or other devices to cause a series of operational steps to be performed on the computer, other programmable apparatus or other devices to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide processes for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
- One or more databases may be included in a host for storing and providing access to data for the various implementations.
- any databases, systems, or components of the present disclosure may include any combination of databases or components at a single location or at multiple locations, wherein each database or system may include any of various suitable security features, such as firewalls, access codes, encryption, de-encryption and the like.
- the database may be any type of database, such as relational, hierarchical, object-oriented, and/or the like. Common database products that may be used to implement the databases include DB2 by IBM, any of the database products available from Oracle Corporation, Microsoft Access by Microsoft Corporation, or any other database product.
- the database may be organized in any suitable manner, including as data tables or lookup tables.
- Association of certain data may be accomplished through any data association technique known and practiced in the art.
- the association may be accomplished either manually or automatically.
- Automatic association techniques may include, for example, a database search, a database merge, GREP, AGREP, SQL, and/or the like.
- the association step may be accomplished by a database merge function, for example, using a key field in each of the manufacturer and retailer data tables. A key field partitions the database according to the high-level class of objects defined by the key field.
- a certain class may be designated as a key field in both the first data table and the second data table, and the two data tables may then be merged on the basis of the class data in the key field.
- the data corresponding to the key field in each of the merged data tables is preferably the same.
- data tables having similar, though not identical, data in the key fields may also be merged by using AGREP, for example.
- aspects of the present disclosure provide a method that includes capturing a first visual image of a first material piece resulting in a first image data packet pertaining to the first material piece; capturing a second visual image of a second material piece resulting in a second image data packet pertaining to the second material piece, wherein the first material piece has a first chemical signature, and wherein the second material piece has a second chemical signature different than the first chemical signature; processing the first and second image data packets with a machine learning system that has previously learned to visually discern between material pieces having the different chemical signatures; and classifying with the machine learning system the first and second material pieces into two different classifications as a function of the learned visual discernment between material pieces having the different chemical signatures.
- the method may further include sorting the first material piece from the second material piece as a function of the classifications.
- the material pieces may be plastic pieces.
- the first chemical signature may be spectral data measured by a plurality of different sensor systems from at least one sample of a plastic piece of a same type as the first plastic piece, and wherein the second chemical signature may be spectral data measured by the plurality of different sensor systems from at least one sample of a plastic piece of a same type as the second plastic piece.
- the spectral data may pertain to the non-visible spectrum.
- the plurality of different sensor systems may be selected from a group composed of near infrared (“NIR”), medium wavelength Infrared (“MWIR”), and x-ray fluorescence (“XRF”) systems.
- NIR near infrared
- MWIR medium wavelength Infrared
- XRF x-ray fluorescence
- the plurality of different sensor systems may be selected from a group composed of infrared (“IR”), Fourier Transform IR (“FTIR”), Forward-looking Infrared (“FLIR”), Very Near Infrared (“VNIR”), Near Infrared (“NIR”), Short Wavelength Infrared (“SWIR”), Long Wavelength Infrared (“LWIR”), Medium Wavelength Infrared (“MWIR” or “MIR”), X-Ray Transmission (“XRT”), Gamma Ray, Ultraviolet (“UV”), X-Ray Fluorescence (“XRF”), Laser Induced Breakdown Spectroscopy (“LIBS”), Raman Spectroscopy, Anti-stokes Raman Spectroscopy, Gamma Spectroscopy, Hyperspectral Spectroscopy (e.g., any range beyond visible wavelengths), Acoustic Spectroscopy, NMR Spectroscopy, Microwave Spectroscopy, Terahertz Spectroscopy, Differential Scanning Calori
- the first chemical signature may include measurements of organic and inorganic elements or molecules from at least one sample of a plastic piece of a same type as the first plastic piece
- the second chemical signature may include measurements of organic and inorganic elements or molecules from at least one sample of a plastic piece of a same type as the second plastic piece.
- the plastic pieces may be selected from a group of type #1 polyethylene terephthalate (“PET”), type #2 high-density polyethylene (“HDPE”), type #3 polyvinylchloride (“PVC”), type #4 low- density polyethylene (“LDPE”), type #5 polypropylene (“PP”), type #6 polystyrene (“PS”), and type #7 other polymers.
- the first material piece may be polyvinyl chloride. The two different classifications may be different fractions.
- aspects of the present disclosure provide a system that includes a camera configured to capture a first visual image of a first material piece resulting in a first image data packet pertaining to the first material piece, and a second visual image of a second material piece resulting in a second image data packet pertaining to the second material piece, wherein the first material piece has a first chemical signature, and wherein the second material piece has a second chemical signature different than the first chemical signature; a data processing system configured to process the first and second image data packets with a machine learning system that has previously learned to visually discern between material pieces having the different chemical signatures, wherein the machine learning system classifies the first and second material pieces into two different fractions as a function of the learned visual discernment between material pieces having the different chemical signatures; and a sorting device configured to sort the first material piece from the second material piece as a function of the fractions.
- the material pieces may be plastic pieces.
- the first chemical signature may be spectral data pertaining to the non-visible spectrum measured by a plurality of different sensor systems from at least one sample of a plastic piece of a same type as the first plastic piece
- the second chemical signature may be spectral data pertaining to the non-visible spectrum measured by the plurality of different sensor systems from at least one sample of a plastic piece of a same type as the second plastic piece.
- the plurality of different sensor systems may be from a group of near infrared (“NIR”), medium wavelength Infrared (“MWIR”), and x-ray fluorescence (“XRF”) systems.
- the plurality of different sensor systems may be from a group of infrared (“IR”), Fourier Transform IR (“FTIR”), Forward-looking Infrared (“FLIR”), Very Near Infrared (“VNIR”), Near Infrared (“NIR”), Short Wavelength Infrared (“SWIR”), Long Wavelength Infrared (“LWIR”), Medium Wavelength Infrared (“MWIR” or “MIR”), X-Ray Transmission (“XRT”), Gamma Ray, Ultraviolet (“UV”), X-Ray Fluorescence (“XRF”), Laser Induced Breakdown Spectroscopy (“LIBS”), Raman Spectroscopy, Anti-stokes Raman Spectroscopy, Gamma Spectroscopy, Hyperspectral Spectroscopy (e.g., any range beyond visible wavelengths), Acoustic Spectroscopy, NMR Spectroscopy, Microwave Spectroscopy, Terahertz Spectroscopy, Differential Scanning Calorimetry (“
- the first chemical signature may include measurements of organic and inorganic elements or molecules from at least one sample of a plastic piece of a same type as the first plastic piece
- the second chemical signature may include measurements of organic and inorganic elements or molecules from at least one sample of a plastic piece of a same type as the second plastic piece
- the plastic pieces are selected from the group consisting of type #1 polyethylene terephthalate (“PET”), type #2 high-density polyethylene (“HDPE”), type #3 polyvinylchloride (“PVC”), type #4 low-density polyethylene (“LDPE”), type #5 polypropylene (“PP”), type #6 polystyrene (“PS”), and type #7 other polymers.
- aspects of the present disclosure provide a method that includes determining a chemical signature of each one of a mixture of different plastic pieces with a plurality of different sensor systems; capturing visual images for each of the plastic pieces; digitally associating the visual images with the chemical signature for each plastic piece; determining a specific fraction for sorting of plastic pieces; using the visual images to identifying which of the plastic pieces within the mixture have a chemical signature that falls within the specific fraction; and training a machine learning system to visually identify plastic pieces that fall within the specific fractions, wherein the training is performed with a control group produced from the identified plastic pieces.
- the control group may be composed of captured visual image data of each of the identified plastic pieces.
- the fraction may be composed of a specific combination of organic and inorganic elements or molecules.
- the plurality of different sensor systems may be selected from a group of near infrared (“NIR”), medium wavelength Infrared (“MWIR”), and x-ray fluorescence (“XRF”) systems.
- the mixture of different plastic pieces may be selected from the group of type #1 polyethylene terephthalate (“PET”), type #2 high-density polyethylene (“HDPE”), type #3 polyvinylchloride (“PVC”), type #4 low- density polyethylene (“LDPE”), type #5 polypropylene (“PP”), type #6 polystyrene (“PS”), and type #7 other polymers.
- the plurality of different sensor systems may be selected from a group of infrared (“IR”), Fourier Transform IR (“FTIR”), Forward-looking Infrared (“FLIR”), Very Near Infrared (“VNIR”), Near Infrared (“NIR”), Short Wavelength Infrared (“SWIR”), Long Wavelength Infrared (“LWIR”), Medium Wavelength Infrared (“MWIR” or “MIR”), X-Ray Transmission (“XRT”), Gamma Ray, Ultraviolet (“UV”), X-Ray Fluorescence (“XRF”), Laser Induced Breakdown Spectroscopy (“LIBS”), Raman Spectroscopy, Anti-stokes Raman Spectroscopy, Gamma Spectroscopy, Hyperspectral Spectroscopy (e.g., any range beyond visible wavelengths), Acoustic Spectroscopy, NMR Spectroscopy, Microwave Spectroscopy, Terahertz Spectroscopy, Differential Scanning Calorimetry
- the various settings and parameters (including the neural network parameters) of the components of the system 100 may be customized, optimized, and reconfigured over time based on the types of materials being classified and sorted, the desired classification and sorting results, the type of equipment being used, empirical results from previous classifications, data that becomes available, and other factors.
- the term “or” may be intended to be inclusive, wherein “A or B” includes A or B and also includes both A and B.
- the term “and/or” when used in the context of a listing of entities refers to the entities being present singly or in combination.
- the phrase “A, B, C, and/or D” includes A, B, C, and D individually, but also includes any and all combinations and subcombinations of A, B, C, and D.
- controller refers to non-generic device elements that would be recognized and understood by those of skill in the art and are not used herein as nonce words or nonce terms for the purpose of invoking 35 U.S.C. 112(f).
- substantially refers to a degree of deviation that is sufficiently small so as to not measurably detract from the identified property or circumstance.
- the exact degree of deviation allowable may in some cases depend on the specific context.
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EP4288219A1 (en) | 2023-12-13 |
MX2023009270A (en) | 2024-01-08 |
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KR20230159398A (en) | 2023-11-21 |
JP2024510084A (en) | 2024-03-06 |
TW202301192A (en) | 2023-01-01 |
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JP2024508684A (en) | 2024-02-28 |
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