Patent Application
20050067328
The present invention relates to a method of sorting articles according to their types, especially used industrial articles for the purpose of recycling them. The present invention relates also to a sorting apparatus for this method.
In terms of environmental protection or industrial waste reduction, an increasing number of industrial articles are recycled. Recycling can roughly be classified into reproductive use and reuse. For the reproductive use, respective parts of articles are sorted according to their materials, and reproduced as raw materials. On the other hand, the reuse is using some parts of articles as the same parts of newly produced articles.
As for lens-fitted photo film units, hereinafter called briefly film units, their bodies are collected after the exposed photo filmstrips are removed, and are disassembled through automatic disassembling lines. Functional parts of the disassembled film units, such as exposure units and flash units, are reused, and other plastic parts, such as front and rear covers, are reproduced as raw materials, as disclosed for example in Japanese Laid-open Patent Application No. 6-161042.
As well-known in the art, there are a variety of types of film units which are different from each other in external shape and in internal structure. So the automatic disassembling lines are installed for the respective film unit types. Collected used film units are to be sorted out according to their types, before being fed to the corresponding disassembling lines.
Since the film units have their essential components, like a photographic lens and a flash emitting portion, disposed on its front side, different types have different appearances, especially on the front sides. For this reason, conventional sorting apparatuses discriminate between the different types of film units by photographing the appearances of the film units as they are conveyed in a designated posture. Image data obtained by photographing each film unit are compared to reference image data that are prepared for the respective film unit types, so that the film unit type is discriminated depending upon the results of comparison. Such automatic sorting apparatuses are disclosed in Japanese Laid-open Patent Applications Nos. Hei 6-160048, Hei 8-282837, and 2000-142962.
However, there are those types of film units whose appearances can only be discriminated from other types either on the front sides or on the rear sides. For those film units, the above mentioned prior art sorting apparatuses cannot discriminate the types unless the film units are aligned to direct their discriminative sides toward the camera. Therefore, in order to make the sorting of the film units fully automatically, it is necessary to discriminate between the front side and the rear side of each article, and turn over some of the articles to align them into the designated posture and orientation, before feeding them to the photography station. Because of the need for the side discrimination and posture alignment, the sorting apparatuses of the prior arts are inevitably large in size, and take relatively longer processing time.
It may be possible to prepare the reference images respectively for the front and rear sides of each individual type, so as to determine the type by comparison of a photographed image of either the front side or the rear side of each article with the front side reference images and the rear side reference images. If the different type film units always had different rear side appearances, it could be possible to discriminate the type just by photographing one side of the individual film unit regardless of whether it is front or rear. However, since there are many types of film units that have substantially the same rear side appearances, it is necessary to check the front sides for discriminating between these types.
Furthermore, because the automatic sorting apparatus of the above mentioned prior arts just sorts out the film units as they are sequentially supplied to the sorting apparatus, if the collected film units are biased toward a particular type, the sorting apparatus will feed that type of film units to a corresponding disassembling line more frequently than other types. That is, the conventional sorting apparatus cannot equally feed the film units to the respective disassembling lines. Although the sorting apparatus and the disassembling lines have some buffering functions, if the flow of particular type film units from the sorting apparatus to the corresponding disassembling line exceeds so much over the processing capacity of that disassembling line that the excess of the film units on that line cannot be absorbed by the buffering function, the sorting apparatus itself must interrupt working. This lowers efficiency of the overall recycling operations.
In view of the foregoing, a primary object of the present invention is to provide an apparatus for and a method of sorting articles, whereby articles are sorted out with high efficiency while preventing excessive supply of particular type articles to the following lines that are provided for the respective types of the articles to process.
To achieve the above and other objects in a sorting apparatus for sorting used articles according to their types wherein the articles have different appearances or internal structures from type to type, the present invention comprises a conveyer for conveying the articles of different types in a conveying direction; an imaging device for taking image data from each of the articles as being conveyed on the conveyer; a discrimination device for determining the type of each of the articles on the basis of the image data, and outputting discrimination data for each article; a sorting device disposed behind the imaging device in the conveying direction, for sorting the articles into individual types in accordance with the discrimination data; a number of supply sections for supplying the articles, after being sorted, to a number of disassembling lines which are provided for the respective types of the articles; a buffer section for storing the articles after being sorted; and a control device for controlling the sorting device such that each of the articles is fed from the sorting device through one of the supply sections to a corresponding one of the disassembling lines that is determined in accordance with the type of each article, only while the corresponding disassembling line can afford to process the article, and that each of the articles is fed from the sorting device to the buffer section when the corresponding disassembling line cannot afford to process the article.
According to a preferred embodiment, the control device counts the number of discriminated articles separately from type to type on the basis of the discrimination data, compares the count of each type per unit time with a preset number of articles processed per unit time on the corresponding disassembling line, and controls the sorting device to feed the article to the buffer section when the count per unit time is more than the preset processing number, or to the corresponding disassembling line when the count per unit time is less than the preset processing number.
According to another preferred embodiment, the control device monitors the number of the articles existing on each of the supply sections. Then, the controller controls the sorting device to feed the article to the buffer section when the corresponding supply section cannot further accept the article. When the corresponding supply section can further accept the article, the controller controls the sorting device to feed the article to the corresponding supply section.
It is preferable to provide the sorting apparatus further with a circulating device for feeding the articles from the buffer section back to the conveyer so that the articles are conveyed again through the imaging device to the sorting device.
In another preferred embodiment, the buffer section consists of a number of buffer sections for storing the articles separately from type to type, and the sorting apparatus further comprises a number of supplemental lines connecting each of the buffer sections to a corresponding one of the supply sections. In this embodiment, the controller controls each of the buffer sections to feed the article through the supplemental line to the corresponding supply section when the corresponding disassembling line can afford to process the article.
It is preferable to use an X ray imaging device for taking the image data from the articles. The X ray imaging device applies X-rays to a front side or a rear side of each of the articles to photograph a transparent image of each article. Then the discrimination device can determines the type of each article on the basis of the transparent image. Therefore, it is unnecessary to align the articles so as to direct the same side to the imaging device.
According to the present invention, a method of sorting used articles according to their types comprises the steps of:
The above and other objects and advantages will be more apparent from the following detailed description of the preferred embodiments when read in connection with the accompanied drawings, wherein like reference numerals designate like or corresponding parts throughout the several views, and wherein:
As shown in
The exposure unit 15 is an assembly having photographic mechanisms integrated into one body, including a photographic lens, a shutter mechanism, a film-winding and shutter-cocking mechanism and a winding-lock mechanism. Also a viewfinder optical system is integrated into the exposure unit 15. The exposure unit 15 is removably attached to a front side of the main body portion 14.
The flash unit 16 is attached to the front side of the main body portion 14 beside the exposure unit 15. The flash unit 16 includes a number of metallic components, like a copper foil circuit pattern on a circuit board 18, a power source battery 19, a main capacitor 20 and a reflector of a flash emitting portion 21. Also in the exposure unit 15, many metallic components, like springs, are used as components of the mechanisms. Thus, the film unit 10 is a complex assembly of plastic and metallic components.
As shown in
As well-known in the art, different types of film units are different in contour and appearance. As for the front side of the film unit 10, as shown in
Therefore, the positions of the internal metallic components of the individual film units can be utilized as features of the respective film unit types. According to a preferred embodiment, an X ray imaging device is adopted to take a transparent image of each film unit. Thereby, the type of each individual film unit may be determined on the basis of a transparent image alone that is taken either from the front side or from the rear side of the film unit. As described in detail later, the X ray imaging device takes a transparent image of the film unit.
The transparent image is compared to a number of preset reference images, which have different patterns from each other to represent features of the respective types of film units. The comparison is carried out by a pattern matching method, wherein the transparent image is superposed on each reference image in a memory of an image processor, to check the correspondence between these two images.
Because the permeability to X-rays is different between plastics and metals, plastic components 32 of the film unit 10 are imaged to be white portions, while metallic components 33 are imaged to be black portions. Therefore, the black portions or the images of the metallic components 33 are used as the features of the respective film unit types. The transparent image 30 or 31 taken by the X ray imaging device is compared to the reference images of the respective film unit type, to select the most similar reference image to the transparent image 30 or 31. Then, the film unit 10 is determined to be of the type that is represented by the selected reference image.
Referring to
In the factory, the film units are sorted according to the types through a sorting line 35, and fed to disassembling lines 36, 37 and 38 of the corresponding types respectively. On each disassembling line 36, 37 or 38, the film units go through a deformed unit mending process 39 and an outer casing removal process 40 before a disassembling process 41. In the deformed unit mending process 39, the bottom lid 17 of each film unit is closed. As for such film unit whose bottom lid 17 cannot be closed, the bottom lid 17 is cut away. In the outer casing removal process 40, outer casings of the film units, including the labels 22 and cardboard boxes, are removed. In the disassembling process 41, the parts to reuse, such as the exposure unit 15 and the flash unit 16, are removed and inspected, before being fed to a corresponding assembling line.
As shown in
The throw-in section 43 is to supply randomly different types of film units in irregular postures onto the conveyer 47. The aligning section 44 aligns the conveyed film units such that every film unit directs its front or rear side upward, and is conveyed in a line with its lengthwise direction along the conveying direction and with spacing from one another.
The type discriminating section 45 detects the type of each individual film units, and outputs discrimination data to the controller 51.
The sorting section 46 is provided with a number of sorting mechanisms 52, 53 and 54, which are arranged sequentially along the conveying direction of the conveyer 47. Each of the sorting mechanisms 52, 53 and 54 sorts out film units of an individually predetermined type, e.g. type I, type II or type III respectively, and apportions the sorted film units between a supply line 55, 56 or 57 and a buffer line 58, 59 or 60 respectively. The supply lines 55 to 57 feed the film units to the disassembling lines 36 to 38 for the corresponding film unit types respectively. The butter lines 58 to 60 feed the film units to buffer sections 48 for the corresponding film unit types. Although there are three sorting mechanisms 52 to 54 in
The controller 51 controls overall operations of the sorting line 35. As shown in
Whether to feed the film units to the supply line or to the buffer line is determined depending upon how many film units of the same type has been supplied per unit time, i.e. the number of film units of the individual type as counted per unit time, in comparison with the number of film units processed per unit time through the disassembling line for the corresponding film unit type, i.e. the processing capacity of the individual disassembling line. The processing capacity of the individual disassembling line is predetermined for each type, while the number of film units supplied per unit time varies from type to type and from time to time as well.
For example, if the count per unit time is “10” with respect to the film units of type I, i.e. 10 pieces per minute (pieces/min.), while the predetermined processing capacity of the corresponding disassembling line 36 is 30 pieces/min., the controller 51 drives the sorting mechanism 52 to feed the film units of type I to the supply line 55. If, on the contrary, the count per minute of the film units of type I goes above 30, the controller 51 drives the sorting mechanism 52 to feed the film units of type I to the buffer line 58. Thereby, excessive supply of the film units to the disassembling lines 55 to 57 is prevented. If the count per unit time of the film units of one type is equal to the processing capacity of the corresponding disassembling line, the film units of this type may be feed to either one of the supply line and the buffer line.
Instead that the controller 51 counts the number of film units of each type on the basis of the discrimination data from the discriminating section 45, it is possible to count the number per unit time of film units that are actually fed to the individual disassembling line 36, 37 or 38. In that case, a sensor is disposed on each of the supply lines 55 to 57, to detect and count the film units as going by the sensor. Such a sensor may be disposed immediately behind each sorting mechanism 52, 53 or 54, or at the entrance of each disassembling line 36, 37 or 38.
Alternatively, the apportion at the individual sorting mechanism 52, 53 or 54 may be dependent upon how many film units are exiting on the corresponding supply line 55, 56 or 57, or how many film units the corresponding supply line 55, 56 or 57 can presently accept. The number of film units exiting on each supply line 55, 56 or 57 may be determined by subtracting the number of film units fed from each supply line 55, 56 or 57 to the corresponding disassembling line 36, 37 or 38, on one hand, from the number of film units fed from each of the sorting mechanisms 52 to 54 to the corresponding supply line 55, 56 or 57, on the other hand.
On the assumption that Nm represents the maximum number of film units capable of exiting stably on the individual supply line 55, 56 or 57, and Nt represents the number of film units actually existing on the individual supply line 55, 56 or 57, the controller 51 compares the number Nt with the maximum number Nm for each individual film unit type. If the number Nt is less than the maximum number Nm with respect to one type, the controller 51 judges that the disassembling line for this type can afford to process the film units, so the sorting mechanism 52, 53 or 54 for this type is driven to feed the film unit of this type to the corresponding supply line 55, 56 or 57. On the contrary, if the number Nt is more than the maximum number Nm with respect to one type, the corresponding sorting mechanism 52, 53 or 54 is driven to feed the film unit to the corresponding buffer line 58, 59 or 60.
The number of film units presently acceptable on the individual supply line 55, 56 or 57 is determined by subtracting the number Nt from the maximum number Nm. Therefore, it is possible to feed the film unit to the supply line 55, 56 or 57 when (Nm−Nt) is a positive value, or to the buffer line 58, 59 or 60 when (Nm−Nt) is zero or a negative value. To simplify the structure, it is possible to dispose a sensor for each of the supply lines 55 to 57 at a position to detect if the individual supply line is full, so as to feed the film unit to the corresponding buffer line when the supply line is full.
The tracking sensors 50 are disposed in association with the individual sorting mechanisms 52 to 54, to trace the respective film units by measuring the conveying amount of the conveyer 47 and detecting the film units one by one, as they go past the respective sorting mechanisms 52 to 54.
Since a set of the sorting mechanism, the supply line and the buffer line are provided for each film unit type, and these sets for the respective film unit types are arranged sequentially along the conveying direction of the conveyer 47, it is easy to add another set of sorting mechanism, supply line and buffer line for a new type of film unit.
The buffer sections 48 store the film units as fed through the buffer lines 58 to 60. In the illustrated embodiment, the buffer sections 48 are provided for respective film unit types, e.g. for type I, type II and type III, so as to store the film units separately from one type to another.
But it is possible that a buffer section stores the film units regardless of their type. In that case, the film units are automatically fed back to the throw-in section 43 through the circulating conveyer 49.
In the case where the film units are stored for each type in the respective buffer sections 48, the controller 51 drives only one of the buffer sections 48 at a time to feed back the stored film units of one type to the throw-in section 43 or the aligning section 44. The type of the film units to be fed back is determined with respect to the opening in the capacity of the disassembling lines 36 to 38 or that of the supply lines 55 to 57. That is, the film units of the individual type are fed back only while the disassembling line 36, 37 or 38 for that type or the corresponding supply line 55, 56 or 57 is available. Thereby, the amounts of the film units supplied to the respective disassembling lines 36 to 38 are balanced.
It is alternatively possible to feed back the film units from the buffer sections 48 directly to the corresponding supply line 55, 56 or 57. In that case, as shown in
Now the type discriminating section 45 will be described in detail. The type discriminating section 45 is constituted of an imaging section 70 and an image processing and type determining circuit 71, which are controlled by the controller 51. The imaging section 70 mainly consists of an X ray irradiator and an imaging device, which are disposed stationary in opposition to each other across the conveying surface of the conveyer 47, so that the X ray irradiator applies the X-rays to the front side or the rear side of each individual film unit. Each time the film unit reaches an imaging field of the imaging section 70, which is detected by a sensor, the imaging section 70 starts imaging.
The X ray irradiator applies the X-rays to the film unit as it is conveyed. For example, the imaging device has a linear X ray sensor that outputs linear image data, or data of a line of pixels, each time the film unit is conveyed by a predetermined amount. The linear image data is accumulated in a memory of the imaging device in synchronism with the conveying speed of the film unit, so as to produce 2-dimensional image from the accumulated linear image data on the memory. The planer image data is transferred as a transparent image of the X rayed film unit to the image processing and type determining circuit 71. After each transfer of the 2-dimensional image, the memory of the imaging section 70 is cleared, and begins to accumulate the linear image data. As described above, the transparent image is a gray-scale image wherein the metallic components of the film unit look darker, while the plastic components look lighter.
The image processing and type determining circuit 71 is provided with an image processing circuit, a comparison circuit, ROM and RAM. The ROM or RAM stores the predetermined reference images for the respective film unit types. Each of the reference images represents a characteristic portion of a particular type film unit. Because the power source battery 19 and the flash emitting portion 21 are not so different in size and contour between the different film unit types, the characteristic portions are defined as those portions containing other metallic components, like the spring, having specific contour or size for each type. Take the film unit 10, for example, a portion 75 or 76 as shown in
The transparent image is first subjected to a digital image processing to extract a contour of the film unit 10, as illustrated in the flowchart of
Next, at least a characteristic portion of the transparent image is extracted through an image processing. The characteristic portion is automatically determined by position data stored in association with the reference image, the position data being representative of a relative position of the characteristic portion to the contour of the reference image.
The extracted characteristic portion or portions of the transparent image are individually compared with the corresponding characteristic portion or portions of the reference image of one film unit type. The comparison of the characteristic portion between the transparent image and the reference image is carried out from one type to another, so as to select the most similar reference image to the transparent image. Thus, the type of the film unit 10 as photographed is determined to be the film unit type represented by the most similar reference image. Furthermore, based on the most similar reference image, it is determined which side of the film unit 10, front side or rear side, is photographed.
Next, the transparent image is converted into binary data, and the number of white pixels within the contour is counted. As described above with respect to the film unit 10, most of the components of the flash unit 16, including the copper foil circuit pattern on the circuit board 18, the power source battery 19, the main capacitor 20 and the flash emitting portion 21, are metallic, so that they are represented by black pixels. Because they occupy a certain area within the contour, it is possible to determine based on the number of the white pixels within the contour, whether the photographed film unit contains a flash unit or not. If the count of the white pixels is more than a preset value, it is determined that the photographed film unit does not contain any flash unit, and thus any power source battery. If the count of the white pixels is less than the preset value, it is determined that the photographed film unit contains a flash unit.
Even if it is determined that the film unit contains the flash unit, there may be a case where the power source battery is illegally removed. In order to detect whether the film unit contains the power source battery or not, the number of black pixels within the contour is counted and compared with a second preset value. If the count of the black pixels is less than the second preset value, it is determined that the film unit does not contain any power source battery.
The image processing and type determining circuit 71 sends these discrimination data to the controller 51. The discrimination data include data of the film unit type, data as to whether the battery is contained or not, and data as to which side of the film unit is photographed. Concretely, as shown for example in
The controller 51 sends the discrimination data to the disassembling lines 36 to 38 in synchronism with the feeding of the film units to the respective disassembling lines 36 to 38. The discrimination data are utilized for aligning the film units into the same posture on the disassembling lines 36 to 38, as well as for determining the film units to be subjected to a process of removing the power source batteries on the disassembling lines 36 to 38. Thus, the discrimination data contribute to simplifying the disassembling processes and improving efficiency of disassembling.
Although the present invention has been described with respect to the illustrated embodiment, the present invention is not limited to the above embodiment.
For example, it is possible to photograph a surface image of each individual film unit by use of a solid state imaging device, like a CCD, instead of the X ray imaging device. In that case, the image is taken from one or each side of the individual film unit. Type discrimination of each film unit is carried out on the basis of positions and shapes of the respective features, including the grip portion 28, the photographic lens 23, the lens hood 29, the finder objective window 24, the flash emitting portion 21 and the flash charge button 27. For this purpose, the photographed image is processed into a density distribution pattern, an outline pattern and the like. These patterns are compared with reference image data that represent the characteristic features of the different film unit types.
As the method of discriminating the film unit type on the basis of the transparent image or the surface image, the above embodiment adopts the pattern matching method. Instead, it is possible to use another method, like a window setting method wherein a number of windows are placed at designated positions in a photographed image, and the number of white or black pixels is detected within each window, so as to determine the positions of the characteristic features in each image.
Although the above described embodiments relate to the method and apparatus for sorting the film units, the present invention is also applicable to sorting any other articles into a number of disassembling lines.
Thus, the present invention is not to be limited by the above description, but various modifications will be possible within the scope of the present invention as specified in the appended claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2003-316267 | Sep 2003 | JP | national |
