Adaptive Ejector Valve Array Control for Sorting Accuracy
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Arrays of ejector valves in sorting machines face performance variations due to manufacturing tolerances, wear, temperature, and electromagnetic noise, leading to non-conformal fluid flow and sorting inaccuracies, especially when mixed-age valves are present.
Innovation Solution
A method involving the measurement of temporal response curves for each ejector valve, comparison to a library of stored curves, and adaptation of drive signals to predict and adjust fluid flow, accounting for local electromagnetic effects and valve configurations, ensuring consistent performance across the array.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a large number of ejector valves are arranged in close proximity in an array, then the sorting capacity and throughput are improved, but temperature variations and electromagnetic noise interfere with neighbouring valves causing performance degradation
Solution Approach 1:
The patent applies local quality by individually characterizing and adjusting each ejector valve's temporal response based on its specific position and local environmental conditions in the array. Each valve receives a customized drive signal adaptation rather than a uniform control approach, addressing the local electromagnetic noise and temperature variations affecting each valve differently.
2Productivity
If ejector valves operate for extended periods, then productivity is maintained, but wear and tear causes individual valve performance to diverge leading to non-conformal response
Solution Approach 1:
The patent implements dynamics by continuously monitoring and adapting the drive signals for each ejector valve based on real-time or periodic temporal response measurements. The system dynamically adjusts for wear and performance drift, allowing valves to maintain conformal response characteristics even after extended operation and replacement cycles.
Solution Approach 2:
The system uses feedback by measuring the actual temporal response of each ejector valve and using this information to adapt the drive signals. This closed-loop approach ensures that wear, manufacturing variations, and environmental effects are compensated for, maintaining reliable and consistent valve performance over time.
3Ease of repair
If individual ejector valves are replaced over time, then maintenance and repair are enabled, but the array develops a mixture of old and newer valves with different performance characteristics
Solution Approach 1:
The patent applies parameter changes by measuring the temporal response characteristics of each ejector valve and adjusting the drive signal parameters individually to compensate for differences between old and new valves. This allows mixed-age valve arrays to operate with uniform performance by tailoring control parameters to each valve's specific characteristics.
4Ease of manufacture
If manufacturing tolerances and machining variations exist, then production cost and ease of manufacture are improved, but valve performance varies despite receiving the same control signal
Solution Approach 1:
The system implements self-service by automatically characterizing each ejector valve's temporal response and self-adjusting the drive signals to achieve uniform performance across the array. This eliminates the need for manual calibration or high-precision manufacturing, as the system compensates for variations automatically.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances the accuracy and consistency of sorting by compensating for individual valve wear and environmental variations, maintaining conformal performance even with mixed-age valves and changing environmental conditions.
Implementation Method 1
A mechanism, typically comprising an electromagnet, acts to open each valve in the array selectively in response to a control signal
Data Source
AI summary
A method for providing adaptive control of the flow of a plurality of ejector valves arranged in close proximity to each other in a sorting machine is described. The method comprises measuring a temporal response curve for each ejector valve, comparing the measured temporal response curve for each ejector valve to a library set of previously stored temporal response curves, determining from the comparison a predicted flow for each ejector valve, and adapting a drive signal for each ejector valve in dependence on the predicted flow. Temporal response curves may be measured and compared in a calibration (non-sorting) mode, and real-time feedback of the measured temporal responses in a sorting mode may be used to indicate health of a valve and to further adapt the drive signal to provide conformal performance. The number of neighboring ejector valves may also be taken into account.