Blanking amount correction method and device based on idling detection

Abstract

The invention discloses a blanking amount correction method based on idling detection, and relates to the technical field of feeding equipment, the method comprises the following steps: S1, receiving a planned blanking amount M through a control panel, the control panel integrating data operation and instruction sending functions; s2, the theoretical pulse number P plan is calculated according to the blanking weight K of each circle and the Hall pulse number P of each circle pre-stored by the control panel, and P plan = (M / K) * P; s3, the control panel drives a driving motor of discharging equipment to start discharging, the discharging process is monitored through a state detection sensor which is installed on a material inevitable path at the bottom of a discharging pipeline, and Hall pulses generated only in the period when the state detection sensor judges that the state of materials exists are accumulated to serve as the effective pulse number P actual; s4, the control panel calculates the actual discharging amount M actual according to the effective pulse number P actual, wherein M actual = K * (P actual / P); and S5, the control panel actually transmits the actual discharging amount M to a display unit to be output.

Description

Technical Field

[0001] This invention relates to the field of feeding equipment technology, and more specifically, to a feeding quantity correction method and device based on idling detection. Background Technology

[0002] In modern large-scale farms, intelligent feeders achieve precise feeding of livestock and poultry through automated feeding systems. Accurate measurement of the feed quantity is a key technical indicator for ensuring feeding effectiveness and controlling feed costs. Currently, common feeding measurement methods are mainly divided into two categories: one is a mechanical measurement method that relies on the number of motor rotations to calculate the amount of feed. This involves pre-setting the feed weight corresponding to each motor rotation and combining this with the number of motor rotations (or Hall pulse counts) to indirectly calculate the feed quantity. The other method uses weighing sensors for direct weighing measurement. For example, a suspended weighing module is installed at the feed hopper or feed outlet to directly obtain the feed quantity through changes in weight.

[0003] The first method is simple in structure and low in cost, but when the feeding mechanism (such as the impeller) idles, the motor rotates but no actual material falls, causing the system to count a much larger amount of material than the actual amount, resulting in significant measurement errors. The second weighing method, while more accurate, typically requires the entire equipment or weighing unit to be installed horizontally, and its complex mechanical structure and expensive sensors and circuitry make it difficult to widely apply in complex environments such as farms where cost is a primary concern. Summary of the Invention

[0004] This invention provides a feeding quantity correction method based on idling detection, which can solve the problem in the prior art where the motor is rotating but no actual material is falling, resulting in the system's statistical feeding quantity being much larger than the actual feeding quantity, and significant measurement error.

[0005] A feeding quantity correction method based on idling detection is applied to a feeding device. The method includes: S1, receiving the planned feeding quantity M through a control board, the control board integrating data calculation and instruction sending functions; S2, calculating the theoretical pulse number Pplanned based on the feeding weight K per revolution and the number of Hall pulses P per revolution pre-stored on the control board, where Pplanned = (M / K) × P; S3, the control board drives the drive motor of the feeding device to start feeding, and monitors the feeding process through a status detection sensor installed at the bottom of the feeding pipe along the material's inevitable path, wherein the Hall pulses generated only during the period when the status detection sensor determines that there is material are accumulated are taken as the effective pulse number Pactual; S4, the control board calculates the actual feeding quantity Mactual based on the effective pulse number Pactual, where Mactual = K × (Pactual / P); S5, the control board transmits the actual feeding quantity Mactual to the display unit for output.

[0006] The present invention provides a feeding quantity correction method based on idling detection, which has the following beneficial effects compared with the prior art: This material discharge quantity correction method based on idling detection uses a state detection sensor installed at the bottom of the material discharge pipe of the feeding equipment to determine the material presence or idling status of the feeding mechanism in real time. Only the Hall pulses generated during the material presence period are accumulated as the effective pulse count P. This completely avoids the significant error problem in traditional mechanical metering where the motor continues to count normally during idling, leading to the system's statistical discharge quantity being much greater than the actual discharge quantity. Moreover, this method does not rely on high-precision weighing sensors and complex horizontal installation structures. Instead, it establishes a pulse-discharge quantity correlation logic by presetting the discharge weight K per revolution and the pulse count P per revolution, and calculates the discharge quantity by combining it with the actual M. This method eliminates the need for high-cost sensors and supporting circuits in weighing methods and avoids the stringent horizontal requirements of the installation environment. It is especially suitable for complex on-site environments such as farms where equipment cost is sensitive.

[0007] Further, in step S3, the method for determining whether there is material or no material includes: comparing the detection signal of the state detection sensor with a preset amplitude threshold and / or fluctuation threshold; when the amplitude of the detection signal is higher than the amplitude threshold and / or the fluctuation amplitude is greater than the fluctuation threshold, it is determined to be a material-containing state; otherwise, it is determined to be a material-free state.

[0008] Furthermore, the state detection sensor is a strain gauge or a load cell.

[0009] Furthermore, before determining the current state, the analog weight signal output by the sensor is first converted into a digital level signal, where a high level represents a material-containing state and a low level represents a material-free state.

[0010] Furthermore, in step S3, if no material is detected after a preset time has elapsed since the material feeding task was started, it is determined that the hopper is empty or the material feeding is blocked, and an alarm is triggered and / or the material feeding operation is stopped.

[0011] A feeding quantity correction device includes a control board, a Hall sensor, and a status detection sensor. The Hall sensor and the status detection sensor are both electrically connected to the control board. The control board is installed on the feeding equipment. The Hall sensor is installed on the drive motor of the feeding equipment. The status detection sensor is installed inside the feeding equipment.

[0012] Furthermore, the control board includes a pulse acquisition unit and a status determination unit. The pulse acquisition unit is used to acquire the pulse signal of the Hall sensor in real time, and the status determination unit is used to acquire and process the detection signal of the status detection sensor in real time.

[0013] Furthermore, the status detection sensor is located directly below the impeller of the feeding device.

[0014] Furthermore, the status detection sensor is attached to the feed pipe below the impeller.

[0015] Furthermore, the feeding device is an intelligent feeder. Attached Figure Description

[0016] Figure 1 This is a flowchart of a feeding quantity correction method and correction device based on idling detection according to an embodiment of the present invention; Figure 2 This is a framework diagram of a feeding quantity correction method and correction device based on idling detection according to an embodiment of the present invention; Figure 3 This is an information acquisition diagram of a feeding quantity correction method and correction device based on idling detection according to an embodiment of the present invention. Detailed Implementation

[0017] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings showing multiple embodiments according to this application. It should be understood that the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. All other embodiments obtained by those skilled in the art based on the embodiments described in this application without creative effort will fall within the scope of protection of this application.

[0018] Unless otherwise defined, all technical and scientific terms used in this application have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains; the terminology used in the description of this application is for the purpose of describing specific embodiments only and is not intended to limit this application; the terms "comprising," "including," "having," "containing," etc., in the description, claims, and accompanying drawings of this application are open-ended terms. Therefore, "comprising," "including," or "having" refers to, for example, a method or apparatus having one or more steps or elements, but is not limited to having only these one or more elements. The terms "first," "second," etc., in the description, claims, or accompanying drawings of this application are used to distinguish different objects, not to describe a specific order or hierarchy. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, unless otherwise stated, "a plurality of" means two or more.

[0019] In the description of this invention, it should be understood that the terms "upper", "lower", "left", "right", "front", "rear", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0020] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," "linking," and "attachment" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0021] It should be emphasized that when the term "comprising / including" is used in this specification, it is used to explicitly indicate the presence of the stated feature, integer, step, or component, but does not exclude the presence or addition of one or more other features, integers, steps, parts, or groups of features, integers, steps, or parts.

[0022] In this application, the term "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, or B existing alone. Additionally, in this application, the character " / " generally indicates that the preceding and following related objects have an "or" relationship.

[0023] See Figure 1 This invention provides a feeding quantity correction method based on idling detection, applied to a feeding device. The method includes: S1, receiving the planned feeding quantity M through a control board, which integrates data calculation and instruction sending functions; S2, calculating the theoretical pulse number Pplanned based on the feeding weight K per revolution and the number of Hall pulses P per revolution pre-stored on the control board, where Pplanned = (M / K) × P; S3, the control board drives the drive motor of the feeding device to start feeding, and monitors the feeding process through a status detection sensor installed at the bottom of the feeding pipe along the material's path, wherein the Hall pulses generated only during the period when the status detection sensor determines that there is material are accumulated, which are taken as the effective pulse number Pactual; S4, the control board calculates the actual feeding quantity Mactual based on the effective pulse number Pactual, where Mactual = K × (Pactual / P); S5, the control board transmits the actual feeding quantity Mactual to the display unit for output.

[0024] In this embodiment, for mechanical metering methods that rely on the number of motor rotations, this method uses a state detection sensor installed at the bottom of the material feeding pipe of the feeding equipment to determine in real time whether the feeding mechanism is in operation with material or idling. Only the Hall pulses generated during the material-in-process state are accumulated as the effective pulse count P, which completely avoids the significant error problem in traditional mechanical metering where the motor continues to count normally during idling, leading to the system's statistical feeding quantity being much greater than the actual feeding quantity. For direct weighing methods using suspended weighing modules, this method does not rely on high-precision weighing sensors and complex weighing systems. Instead of a complex horizontal installation structure, this method establishes a logic linking pulses and material quantity by pre-setting the material feeding weight K per revolution and the number of pulses P per revolution. Combined with the calculation M_actual = K × (P_actual / P), the material feeding quantity is calculated. This eliminates the need for high-cost sensors and supporting circuits in weighing methods and avoids the stringent horizontal requirements of the installation environment. It is especially suitable for complex environments such as farms where equipment costs are sensitive. While retaining the advantages of simple and low-cost traditional mechanical metering structures, it achieves measurement accuracy close to that of weighing methods, balancing practicality and economy, and is easy to promote and apply on a large scale.

[0025] Specifically, after receiving a planned request from the platform or buttons, such as a 2000g material unloading requirement, the control board calculates the required 10 rotations based on a known material weight, such as 200g. This is then converted into a plan for the number of motor rotations. The control board controls the number of motor rotations and continuously counts the number of Hall pulses generated by the motor rotation; for example, 500 pulses are generated per rotation by default. Simultaneously, the control board acquires the signal change amplitude and fluctuation magnitude from strain gauges or load cells. A processor converts this data; exceeding a certain threshold indicates material presence, while below it indicates no material. This conversion can be performed by a separate module or by the control board. The system then obtains the number of Hall pulses indicating material presence; for example, if 2500 pulses are detected at the material position, the actual unloading position Mactual = 200g. 2500 / 500=1000g.

[0026] For example, if M = 2000g, P is the number of Hall pulses in one revolution, or P = 500, and K is the material weight in one revolution, or K = 200g, then the planned P = 2000g / 200g. 500 = 5000. If the motor rotates 5000 pulses and there is material only in 2500 pulses, then P_actual = 2500, and M_actual = 200g. 2500 / 500=1000g, indicating that 1000g of material was fed this time.

[0027] like Figure 1As shown, in step S3, the method for determining whether there is material or no material includes: comparing the detection signal of the state detection sensor with a preset amplitude threshold and / or fluctuation threshold; when the amplitude of the detection signal is higher than the amplitude threshold and / or the fluctuation amplitude is greater than the fluctuation threshold, it is determined to be a material-containing state; otherwise, it is determined to be a material-free state.

[0028] In this embodiment, the judgment logic relies on a state detection sensor (such as a strain gauge attached to the inner wall of the pipe and flush with the material channel) installed at the bottom of the material feeding pipe along the material's inevitable path, and a control board with pre-stored threshold parameters. On the one hand, it can accurately avoid the defect of traditional mechanical metering that "relying solely on motor pulse counting cannot identify idling." When the impeller is idling, the weight signal amplitude collected by the strain gauge is low (below 0.5V) and fluctuates little (below 0.2V). The control board determines that there is no material and does not accumulate pulses during this period, completely avoiding falsely high measurements caused by idling. On the other hand, compared with traditional weighing and metering that relies on high-precision sensors and The stringent requirement of horizontal installation is addressed by this dual-threshold judgment method, which eliminates the need for direct weighing. It achieves state identification solely through the signal amplitude and fluctuation characteristics collected by strain gauges. Strain gauge installation does not require adjusting the pipe's level, and the control board can dynamically adjust the threshold via a remote platform (e.g., lowering the fluctuation threshold to 0.1V when switching to powder materials). This adapts to different material types, reducing sensor and structural design costs while avoiding misjudgments caused by substandard leveling during on-site installation. It is particularly suitable for complex scenarios such as uneven feed particle size in livestock farms and variable properties of industrial materials, ensuring judgment accuracy while also considering the equipment's versatility and economy.

[0029] Specifically, the condition detection sensor is a strain gauge or a load cell.

[0030] In this embodiment, when a strain gauge is used, its specific structure is attached to the surface of a bearing substrate at the bottom of the material feeding pipe, which is the necessary path for the material. No complex modifications to the original cavity, impeller, or other components of the feeding equipment are required; signal acquisition can be achieved simply by adhesive bonding. Furthermore, the strain gauge itself is inexpensive (far lower than traditional suspended load cells). Combined with a threshold comparison method, it can accurately capture the impact weight signal generated by the falling material on the metal substrate (signal amplitude higher than the threshold and fluctuation greater than the threshold when there is material) and the stable signal when the impeller is idling (signal amplitude low and fluctuation small when there is no material). This avoids the errors caused by the lack of idling recognition in traditional mechanical metering and eliminates the cost of complex structures. When a load cell is used, an adapter for the bottom of the pipe is selected here. The simplified load cell (not the complex structure of traditional suspended load cells that require overall support) does not require horizontal installation of the entire device. It only needs to be fixed below the pipeline to receive the falling material. Its detection signal can be flexibly adapted to the weight characteristics of different materials (such as pelleted feed and powdered materials) through threshold comparison. For materials with high density, the amplitude threshold can be emphasized, and for light and easily floating materials, the fluctuation threshold can be emphasized. It retains the signal sensitivity of the load cell while avoiding the strict requirements for installation accuracy and the high cost of supporting circuits of traditional suspended load cells. Ultimately, both types of sensors can work stably in complex environments such as farms where there is limited space for equipment modification, balancing the accuracy of material presence / absence detection, the convenience of installation, and cost-effectiveness.

[0031] like Figure 1 As shown, before determining the current state, the analog weight signal output by the sensor is first converted into a digital level signal, where a high level represents a material-containing state and a low level represents a material-free state.

[0032] In this embodiment, analog signals are susceptible to fluctuations and distortions caused by equipment vibration and dust interference in complex scenarios such as farms. However, the discrete characteristics of digital level signals can achieve precise synchronization with the pulse acquisition unit of the control board. When the control board receives Hall pulse signals, it can directly and quickly determine whether the corresponding pulse indicates a feeding state through high and low level logic. There is no need to perform complex filtering operations on continuous analog signals, which simplifies the data processing flow of the control board and reduces the hardware computing load.

[0033] Specifically, such as Figure 3 As shown, the function of the idling sensor is as follows: when the impeller is loaded and rotating, the sensor will collect a high-level weight signal with large fluctuations due to the weight of the feed, and convert it into an output level signal, which is high level here; when the impeller is not loaded and rotating, the sensor will collect a low-level weight signal with small fluctuations due to the absence of feed, and convert it into an output level signal, which is low level here.

[0034] Furthermore, in step S3, if no material is detected after a preset time has elapsed since the material feeding task was started, it is determined that the hopper is empty or the material feeding is blocked, and an alarm is triggered and / or the material feeding operation is stopped.

[0035] In this embodiment, when the control board drives the drive motor to start the feeding task, the built-in timing unit is simultaneously triggered to start timing. The status detection sensor continuously transmits the collected weight signal to the status judgment unit of the control board. If the accumulated time of the timing unit reaches the preset value and the status judgment unit still does not receive a high-level signal representing "material present", it immediately determines that the hopper is empty (no material to feed) or the feeding is blocked (material is stuck in the impeller or pipe). At this time, the execution command module of the control board simultaneously outputs two signals. One signal is sent to the alarm module (such as an audible and visual alarm) electrically connected to the control board to prompt the staff to handle the situation in time through sound and light. The other signal is sent to the drive motor to cut off the power supply to the motor to stop the feeding operation. This avoids the energy waste and motor overload damage caused by the continuous idling of the motor when the hopper is empty or blocked in the traditional mechanical metering method, and extends the service life of the equipment. On the other hand, it reduces production problems such as feeding delays in farms and material shortages in industrial batching caused by feeding interruptions.

[0036] like Figure 2 As shown, a feeding quantity correction device includes a control board, a Hall sensor, and a status detection sensor. Both the Hall sensor and the status detection sensor are electrically connected to the control board. The control board is installed on the feeding equipment, the Hall sensor is installed on the drive motor of the feeding equipment, and the status detection sensor is installed inside the feeding equipment.

[0037] In this embodiment, the control board, as the core processing unit, is installed on the main body of the feeding device. It can directly integrate the device's operating data, avoiding signal delays or disconnections caused by decentralized control. At the same time, through electrical connections with Hall sensors and status detection sensors, it enables real-time data interaction among the three. The Hall sensors are specifically installed on the drive motor of the feeding device, which can directly collect the original pulse signals generated by the motor rotation, providing reliable rotational basis data for calculating the feeding amount. The status detection sensors are installed inside the feeding device, which can capture the status signals when the material passes through at close range. Combined with the real-time signal processing of the control board, it can accurately identify the states of material presence and idling.

[0038] Specifically, the control board includes a pulse acquisition unit and a status judgment unit. The pulse acquisition unit is used to acquire the pulse signal of the Hall sensor in real time, and the status judgment unit is used to acquire and process the detection signal of the status detection sensor in real time.

[0039] In this embodiment, the pulse acquisition unit is electrically connected to the Hall sensor, enabling it to capture every pulse signal generated by the motor rotation in real time, providing accurate raw data support for subsequent effective pulse selection. The state judgment unit is directly linked to the state detection sensor, enabling it to instantly acquire and process the weight signals output by the sensor (such as the fluctuation signals of the strain gauge or the weight data of the weighing sensor), quickly determining whether there is material or not. Furthermore, the integration of the two units onto the same control board achieves synchronous coordination between pulse acquisition and state judgment.

[0040] The status detection sensor is located directly below the impeller of the feeding device, and is attached to the feeding pipe below the impeller. The feeding device is an intelligent feeder.

[0041] In this embodiment, by placing the status detection sensor directly below the impeller of the intelligent feeder and attaching it to the feeding pipe below the impeller, since the impeller is the core feeding execution component of the intelligent feeder, the material will fall vertically into the feeding pipe directly below it after the impeller rotates. The sensor located at this position can directly capture the weight signal of the material during the falling process, avoiding material omission or misjudgment due to the installation position deviation, and effectively solving the counting error problem of the motor running but no material when idling in traditional mechanical metering.

[0042] The above-disclosed embodiments are merely a few specific examples of the present invention. However, the embodiments of the present invention are not limited thereto, and any variations that can be conceived by those skilled in the art should fall within the protection scope of the present invention.

Claims

1. A method of correcting a discharge amount based on idle detection, characterized by, The method is applied to a discharging device, and comprises the following steps: S1, receiving a planned discharging amount M through a control panel, wherein the control panel integrates data operation and instruction sending functions; S2, calculating a theoretical pulse number P planned according to a pre-stored discharging weight K per circle and a Hall pulse number P per circle of the control panel, wherein P planned = (M / K) × P; S3, starting discharging by driving a driving motor of the discharging device, and monitoring the discharging process through a state detection sensor installed in a material path at the bottom of a discharging pipeline, wherein a Hall pulse generated only during a material state determined by the state detection sensor is accumulated as an effective pulse number P actual; S4, calculating an actual discharging amount M actual according to the effective pulse number P actual by the control panel, wherein M actual = K × (P actual / P); S5, transmitting the actual discharging amount M actual to a display unit for output.

2. The idle reduction based trim correction method of claim 1, wherein, In step S3, the method for determining the material state or the non-material state comprises: comparing a detection signal of the state detection sensor with a preset amplitude threshold value and / or a fluctuation threshold value; when the amplitude of the detection signal is higher than the amplitude threshold value and / or the fluctuation amplitude is greater than the fluctuation threshold value, the material state is determined, otherwise, the non-material state is determined.

3. The idle reduction based trim correction method of claim 1, wherein, The state detection sensor is a strain gauge or a load cell.

4. The idle reduction based trim correction method of claim 3, wherein, Before determining the current state, the analog weight signal output by the sensor is converted into a digital level signal, wherein a high level represents the material state and a low level represents the non-material state.

5. The idle reduction based trim correction method of claim 1, wherein, In step S3, if the material state is not detected after the discharging task is started for a preset time length, it is determined that the material bin is empty or the discharging is blocked, and an alarm and / or the discharging operation is stopped.

6. A blanking amount correction device characterized by comprising: The discharging amount correction device is applied to the method according to any one of claims 1 to 5, and comprises a control panel, a Hall sensor and a state detection sensor, wherein the Hall sensor and the state detection sensor are electrically connected with the control panel, the control panel is installed on the discharging device, the Hall sensor is installed on a driving motor of the discharging device, and the state detection sensor is installed in the discharging device.

7. The material quantity correction device according to Claim 6, wherein The control panel comprises a pulse collection unit and a state judgment unit, wherein the pulse collection unit is used for collecting pulse signals of the Hall sensor in real time, and the state judgment unit is used for acquiring and processing detection signals of the state detection sensor in real time.

8. The material quantity correction device according to Claim 6, wherein The state detection sensor is located directly below an impeller of the discharging device.

9. The material quantity correction device according to Claim 8, wherein The state detection sensor is attached to the discharging pipeline below the impeller.

10. The material quantity correction device according to Claim 6, wherein The discharging device is an intelligent feeder.

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