Adaptive Flow Measurement System for Conveyor Mixing Accuracy
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Solution Overview
Problem
Existing methods for measuring the flow rates of component materials in continuous mixing processes are inaccurate due to variables such as the size, texture, and weight of individual portions, which affect the movement of materials on conveyors and the dispensation of second component materials.
Innovation Solution
A system that uses high-fidelity weighing machines to accurately measure the total mass of blended products and corrects the measurements of less accurate weighing machines and dispensers by identifying reliable sources of mass data and applying correction factors based on the physical properties and operational variables of the materials and equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional weighing machines are used to measure component material flow rates, then the measurement system is simpler and less costly, but the measurement accuracy deteriorates due to variables affecting material movement and dispensation
Solution Approach 1:
The patent introduces correction factors as an intermediary element between the conventional weighing machines and the true mass values. These correction factors account for variables affecting material movement and dispensation, allowing standard weighing machines to achieve high measurement accuracy without requiring expensive high-fidelity equipment at every measurement point
Solution Approach 2:
The system implements feedback by using high-fidelity weighing machines at strategic locations to measure actual mass values, comparing these against measurements from conventional weighing machines, and using the differences to calculate and apply correction factors that continuously improve measurement accuracy throughout the system
2Measurement precision
If high-fidelity weighing machines are deployed at every measurement point, then measurement accuracy is maximized, but the system cost and complexity increase significantly
Solution Approach 1:
The patent segments the measurement system into two functional parts: high-fidelity weighing machines positioned at strategic locations to establish reference measurements, and conventional weighing machines equipped with correction factors for routine measurements. This segmentation allows high accuracy to be achieved system-wide without deploying expensive equipment at every measurement point
Solution Approach 2:
The system creates a virtual copy of the high-fidelity measurement capability by calculating correction factors from reference measurements and applying them to conventional weighing machines. This allows the benefits of high-fidelity measurement to be replicated across multiple measurement points without the associated costs
3Measurement precision
If correction factors are applied to account for physical properties and operational variables, then measurement accuracy improves, but the measurement and correction process becomes more complex
Solution Approach 1:
The system performs preliminary action by pre-calculating correction factors that account for physical properties of materials and operational variables of equipment before actual measurements are taken. These correction factors are stored and automatically applied, eliminating the need for real-time complex calculations and reducing the difficulty of the measurement process
Data Source
AI summary
A method and system for correcting mass flow rate measurements relating to a conveyor used to move a stream of first component material portions to and through a mixing station in which a second component material is dispensed in a predetermined mass percentage of the mass of the first component material portions. The correction of the measurements is adapted to correct for inaccuracies that arise in the measurements due to, for example, differences in the first component material portions properties, differences in the second component material properties, environmental conditions, drift of electronic instruments, and changing conditions that occur during extended use of an upstream conveyor that delivers first component material portions to the mixing station.