Air Seeder Meter Calibration Using Variable Speed and Dual Sensors
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Solution Overview
Problem
Manual calibration of product distribution machines, such as air seeders, is time-consuming and often not performed frequently enough due to inefficiencies, and existing mass flow sensors have limitations in accurately measuring product flow rates across various conditions and materials.
Innovation Solution
A method and system where the meter drive speed is varied during calibration to increase the accuracy of mass flow sensors, allowing for real-time measurement of product flow rates while the machine is in motion, using a combination of optical and impact mass flow sensors to enhance accuracy across different conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual calibration is performed by turning the meter a given number of revolutions while capturing product, then calibration accuracy can be determined, but the process is time-consuming and represents non-productive time
Solution Approach 1:
The patent replaces manual mechanical calibration operations with automated optical and impact sensors that continuously measure product flow rate. The optical sensor uses light reflection principles to detect product movement, while the impact sensor measures force exerted by falling product, eliminating the need for manual meter revolutions and product capture.
Solution Approach 2:
The calibration process transitions from discrete manual measurements to continuous automated sensing. Sensors continuously measure product flow rate during machine operation, allowing calibration to occur during productive work rather than requiring separate calibration stops.
2Productivity
If mass flow sensors are used to measure product flow rate in real time, then calibration can be performed during operation, but the sensors have limitations and may not accurately measure flow rates for all materials and delivery rates
Solution Approach 1:
The measurement system is divided into two separate sensor types, each optimized for specific measurement ranges and material characteristics. The optical sensor handles certain flow rates and material types, while the impact sensor handles others, allowing the system to segment the measurement domain to achieve broader accuracy.
Solution Approach 2:
The system changes measurement parameters by selecting different sensor types based on operating conditions. The controller switches between optical and impact sensor readings depending on the material being measured and the delivery rate, optimizing measurement accuracy for each specific condition.
3Productivity
If the meter is operated at nominal speed during calibration, then the machine can operate efficiently, but sensor accuracy may be reduced at certain flow rates
Solution Approach 1:
The system dynamically adjusts meter speed during calibration operations. The controller varies the meter rotational speed to optimize sensor measurement accuracy, then uses the calculated mass flow rate per revolution to determine the correct operating speed for the desired delivery rate.
Solution Approach 2:
The system uses sensor measurements to provide feedback to the controller, which then calculates the mass flow rate per revolution and determines the appropriate meter speed setting. This closed-loop feedback ensures accurate calibration and optimal operating speeds.
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 reduces non-productive time by enabling more frequent and accurate calibration of product distribution rates, ensuring precise metering even under varying conditions and materials, thereby improving operational efficiency.
Implementation Method 1
a combination of optical and impact mass flow sensors to enhance accuracy across different conditions
Implementation Method 2
a combination of optical and impact mass flow sensors to enhance accuracy across different conditions
Data Source
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AI summary
A product distribution machine (10) and method of calibrating a meter of a product distribution machine (10), such as an agricultural air seeder is shown. The system uses one or both of optical and mass flow sensors (70, 120) to measure the product flow rate. The sensors (70, 120) are used to measure mass flow rate during a calibration process while the machine (10) is in use. To improve sensor accuracy during the calibration process, the meter speed is changed to change the product flow rate to a rate at which the sensor accuracy is increased.