Robotic Sorting System

The Waste Robotics Artificial Intelligence (AI) Sorter and two Fanuc Robotic Arms were received at the RRF in Fosston. The AI sorter uses a database of physical characteristics and properties to identify target materials and coordinates the target materials removal from the passing material stream on the conveyor. The removal is coordinated by the AI sorter as to which robotic arm is to pick each individual targeted material and tells it when and where that material will be when the arm moves to remove it.   

Targeted materials to be removed from the conveyor belt are based on the material stream being processed. When running garbage through the system, the robotic sorters will remove the special compostable bags of organics (co-collected with garbage) and wet, unrecyclable cardboard not removed by the manual sorters for recycling. When running single stream recyclables the robotic system will remove any bags of material on the belt (the system cannot process material that is not loose and able to be sorted for recycling) and loose plastic film (contaminant).   

The Matthiessen Bag Opener was received at the RRF in Fosston. The bag opener is specialized equipment, which utilizes hanging “hammers” that hold bagged garbage in place while knives on a rotating drum slice through and invert the bags, which results in the bags being emptied and materials inside being able to be separated. Many garbage bags are designed to resist puncture and not allow the otherwise recyclable materials inside to release for processing. The new bag opener should allow the MRF to identify and remove more recyclable materials from the garbage processed.

Titus receives loads of equipment for the project, including supports, platforms, chutes, conveyors, and railings. Much of the equipment to be utilized has been constructed, fabricated, and painted at their CA facility and shipped by truck to the RRF.  

With the receipt of all of the large equipment on-site (bag opener, robots, and fines screen) the major integration project begins. Titus MRF Services begins modification of conveyor belts and chutes, and prepares the area for the robotic sorters to be installed. This involves a significant amount of demolition and modification. A new robotic sorting area needs to occur after the manual sorting station, and the platform for the AI sorter and robotic arms needs to be created. Discharge chutes for captured materials from the robots need to be created.

The first major part of the integration project is to remove the OCC (cardboard) screen, modify its platform to adjust height and accommodate new conveyor belts, and reinstall it at a different location and in a different direction. These changes allow for the addition of the bag opener and AI robotic sorters.

The area that was under the cardboard screen is modified for the installation of the bag opener. The cardboard screen had previously been relocated and reoriented to allow for the installation of the bag opener. The bag opener will receive the waste that wasn't removed by the manual presort area and not extracted by the robots. As bagged recyclables are to be removed by the robots, the bag opener will receive recyclables, but the hanging “hammers” will be retracted in order to allow cardboard to pass through without hanging up on the system. The bag opener should make the trommel more efficient at separating materials for further processing.

The new robotic sorting station is constructed and prepared for the installation of the robots.  (Pictured:  The new sorting area constructed to allow for the new robotic sorting system to be integrated)  A new, wide sorting conveyor is added. Materials passing by the manual sorters will drop onto a higher speed belt that passes under the AI sorter and by two robotic sorters. A space has been added for a future third robotic sorter if needed.  The platform is constructed to account for the stresses and weights of the robotic system components that will be mounted to it. The robotic sorting system requires a protective cage to be installed around the area so the robotic arms do not pose a threat to workers.  A new walkway is constructed to access all parts of the MRF and do maintenance and upkeep. The sorting area has chute enclosures for the robots to drop targeted materials. These chutes will converge and allow for the collection of large volumes of materials at ground level.

The robotic sorting system installation begins. The AI Sorter – or ‘eyes’ of the system – is the first piece of the sorting system to be installed. Legs need to be attached to the AI sorter and positioned so it can scan the entire width of the conveyor belt to detect and identify target materials. It is to be connected to an AI cabinet – or ‘brain’ of the system - which contains the program, database, and coordinates targeted materials to be removed by the robotic arms that will be installed further down the conveyor line.

Both of the robotic arms are installed down from the AI sorter. The robotic arms will be connected to the AI sorter, and programmed to work in a coordinated fashion designed to prioritize the removal of the specialized compostable bags of organics before the non-recyclable cardboard. Non-recyclable cardboard will be removed when present and when no compostable bags are detected. Which robotic arm removes what material is coordinated to reinforce that priority, and also to maximize material removal.  

The robotic cage is installed around the entire robotic sorting system. Due to the size, speed, power, and range of the robotic arms, entry into the work area while in operation would be very dangerous. The cage encloses the danger area, and access to the area while in operation would disable the robotic sorter.