Auger Leveling for Bulk Material Density and Plugging
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Solution Overview
Problem
Existing bulk material leveling and volumetric measuring apparatuses face challenges in maintaining consistent density and are prone to plugging due to excess material, leading to inconsistent volumetric feed rates and potential material binding.
Innovation Solution
A conveyor system equipped with selectively rotatable augers and a shutoff gate, where the augers lift and level bulk material by cutting into it with helical flighting, and excess material is thrown backward, maintaining consistent density and controlling the volumetric feed rate by adjusting the auger height and conveyor speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a gate is used to scrape excess bulk material and level the top surface, then the bulk material top surface can be leveled to a desired height, but the density of the bulk material becomes inconsistent and the material may bind at the gate causing plugging
Solution Approach 1:
The patent removes the traditional gate structure that causes binding and plugging. Instead, it uses an auger mechanism that lifts and removes excess material from the top surface, extracting the problematic gating function while eliminating the harmful binding effect. The auger terminal end lifts material vertically rather than scraping it horizontally, preventing material accumulation and plugging.
Solution Approach 2:
The auger acts as an intermediary mechanism between the bulk material and the leveling function. Rather than using a gate that directly contacts and binds material, the auger serves as a mediating device that lifts and transports excess material away from the conveyor surface, preventing direct binding while achieving the leveling objective.
2Manufacturing precision
If knives are used to level off the top surface by throwing excess material backwardly, then the bulk material top surface can be leveled, but the knives compress the material causing inconsistent densities and material may be thrown forwardly if excess accumulates
Solution Approach 1:
The patent removes the knife mechanism that compresses and inconsistently densities material. Instead, it employs an auger with helical flighting that lifts material vertically without compression. The auger's rotational motion and helical geometry allow material to be lifted and discarded without the compressive force that creates density variations, thus eliminating the source of inconsistent material composition.
Solution Approach 2:
Instead of using knives to push material backward horizontally (which causes compression and forward throwing), the auger inverts the approach by lifting material vertically upward and then it naturally falls back. This inversion of the leveling mechanism eliminates the compressive force and prevents the material from being thrown forwardly, maintaining consistent density.
3Device complexity
If the width of the conveyor surface and height of side walls are fixed, then the structure is simple, but the volumetric feed rate cannot be precisely controlled without accurate depth measurement
Solution Approach 1:
The auger leveling mechanism serves dual purposes: it levels the bulk material top surface to a desired height while simultaneously defining the precise depth measurement reference. By making the auger terminal end the reference point for both leveling and depth measurement, the system eliminates the need for separate measurement devices. The auger's position and dimensions provide self-contained reference for volumetric control.
Solution Approach 2:
The auger mechanism performs multiple functions: it levels the bulk material, defines the depth reference for volumetric measurement, and controls the material discharge. This multi-functionality eliminates the need for separate measurement and control devices, maintaining structural simplicity while achieving precise volumetric feed rate control through the integrated auger system.
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
The system effectively levels bulk material to a consistent height, maintains density, and prevents plugging by managing excess material, allowing precise control over the volumetric feed rate and volume transported.
Implementation Method 1
The auger is selectively rotationally driven about its longitudinal axis. The auger terminal end is positioned at a distance from the conveyor carrying surface, whereby bulk material being transported on the conveyor above the distance is lifted by the auger terminal end
Implementation Method 2
the auger includes helical flighting extending along its longitudinal axis and the flighting terminates at the auger terminal end along an edge located substantially perpendicular to the longitudinal axis
Data Source
AI summary
A bulk material leveling and volumetric measuring and feeding apparatus includes a conveyor for transporting bulk material from a hopper to a leveling assembly. The leveling assembly includes a pair of augers located perpendicular to the conveyor and with the auger terminal ends at a desired height from the conveyor. Side walls are provided parallel to the conveyor direction of travel and extend up to the auger terminal ends. Each auger is positioned within a semicircular longitudinal channel of a trough. Bulk material being transported and which is located above the augers terminal ends is lifted by the augers and thrown back towards the hopper. Thus, bulk material being transported under and beyond the leveling assembly is maintained at a desired depth. By monitoring and/or controlling the conveyor speed and the depth of the transported bulk material, the volumetric feed rate and total volume of transported material can be determined and/or controlled. The height of the leveling assembly above the conveyor is selectively adjustable. A shutoff gate is provided downstream of the leveling assembly.