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If you're taking the time to put the cards in a penny sleeve and/or topload a sorting machine wouldn't make much sense as the time it takes to do that you've already sorted them.
How big would it be?
initally i think it would be best to do by the numbers. and also have a battery back up that would let it run for one or two cycles and then shut down incase of power loss, (being plugged in) and if we wanted portability maybe since your desiging this thing have a portable rechargeabel battery pack. also maybe after you get this more in the line of up and running think of this, since we here all have computers, maybe allow us a user interfae program that will allow us too choose otehr options like color numbers or letters or a combo of all. this could also bring the size and weight down in your design too. kepp up the work will be intresting to see what ya come up with.
dave
We're thinking something of a cylinder base maybe 1 to 2 feet in diameter, then hight wise again 1 to 2 feet, but we'll see. we would like to make it small and convientent for the individual user to use easily.
Comparing speed to effectiveness, look at the corresponding ROC curves to determine that. You just have to estimate the average user. If you ask, you will always get 100% correct with 100 times speed up. As a note, not everyone is a perfect sorter either. You can easily determine the ROC's.