Adaptive Grain Feeder Control for Unloader Torque Reduction
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Solution Overview
Problem
Current grain holding systems face issues such as excessive start-up torque and inefficient unloading due to simultaneous operation of cross and vertical conveyors, leading to potential damage and reduced component lifespan, as well as incomplete unloading and high power requirements.
Innovation Solution
A method for adaptive rate control of grain feeding to an unloader conveyor, utilizing separate drives for cross and unloader conveyors, which senses the unloader conveyor's capacity through pressure, speed, or torque conditions to adjust the feeding rate in real-time, allowing for controlled start-up, efficient unloading, and optional operator override for topping off or cleanout.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cross conveyor and unloader conveyor are operated simultaneously, then unloading capacity is maximized, but start-up torque becomes excessive and component lifespan is reduced
Solution Approach 1:
The unloader conveyor is started and allowed to run for a predetermined time period before the cross conveyor is activated. This preliminary operation empties the unloader conveyor, reducing the grain mass that must be accelerated during simultaneous start-up, thereby reducing peak torque requirements while maintaining unloading capacity
Solution Approach 2:
The system operates in periodic cycles where the unloader conveyor runs first to clear its auger, then the cross conveyor feeds grain. This periodic sequencing creates alternating phases of high and low torque demand, preventing sustained excessive torque while maintaining overall productivity
2Productivity
If cross conveyor starts first or simultaneously with unloader conveyor, then grain flow rate is maximized, but grain damage occurs due to grinding and cracking
Solution Approach 1:
The unloader conveyor operates alone for a predetermined time before the cross conveyor starts, preliminarily clearing the auger of accumulated grain. This prevents the cross conveyor from forcing grain into a full unloader, eliminating the grinding and cracking damage while maintaining optimal grain flow rate when both conveyors operate
3Loss of time
If unloader conveyor is shut down immediately with cross conveyor, then system response time is minimized, but residual grain causes excessive start-up torque on next activation
Solution Approach 1:
The cross conveyor is shut off before the unloader conveyor, allowing the unloader to continue running and empty its auger of residual grain. This preliminary shutdown sequence ensures the unloader starts with minimal grain load on subsequent activations, reducing start-up torque while maintaining fast system response
4Productivity
If maximum unload rate is used, then productivity is maximized, but control precision for topping off and filling smaller receptacles is reduced
Solution Approach 1:
The cross conveyor speed is dynamically adjusted based on the operational phase: running at maximum speed during main unloading to maximize productivity, then automatically reducing to lower speeds during topping-off operations to provide precise grain metering control for smaller quantities and smaller receptacles
Data Source
AI summary
The control of an apparatus within a grain holding device for feeding grain to an unloader conveyor operable for conveying the grain from the holding device, includes sensing a predetermined condition or conditions representative of capacity of the unloader conveyor for receiving grain, and adaptively controlling the apparatus for feeding grain to the unloader conveyor in advantageous varying manners responsive to the conditions, including to delay initiation of feeding until the receiving capacity is increased, and to match the grain feed to the capacity. The automatic control can be overridden, to allow user control of unloader speed, and can be configured to allow cleanout of the unloader conveyor.