Auger Meter Module Calibration for Multi-Product Air Carts
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Solution Overview
Problem
Existing air cart metering systems are expensive, require multiple fluted metering rolls for different seed and fertilizer types, are prone to corrosion, and have inefficient calibration processes that are labor-intensive and time-consuming.
Innovation Solution
A modular metering system with removable meter modules and auger mechanisms, allowing for easy replacement and calibration, and a control system for efficient product application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If fluted metering rolls are used for different seed and fertilizer types, then adaptability to different products is improved, but device complexity and cost increase due to requiring multiple rolls
Solution Approach 1:
The auger is designed with a universal helical flight structure that can meter different types of granular materials including seeds and fertilizers by adjusting operational parameters rather than requiring different physical components. The same auger geometry serves multiple product types through parameter variation.
Solution Approach 2:
The system changes operational parameters such as auger rotation speed, feed rate, and housing clearance to adapt to different seed and fertilizer types. By varying these parameters, the single auger design achieves versatility across multiple product types without requiring multiple specialized components.
2Reliability
If the entire metering system is replaced when one component corrodes, then reliability is maintained, but loss of time and cost increase due to full system replacement
Solution Approach 1:
The metering system is divided into modular components including the auger, housing, and drive mechanism. The auger can be independently removed and replaced by accessing it through the discharge opening, allowing selective replacement of only the corroded component rather than the entire system.
Solution Approach 2:
The auger is designed to be extractable through the discharge opening of the housing without disassembling the entire metering system. This extraction capability enables rapid replacement of the auger component while leaving the rest of the system in place, significantly reducing replacement time.
3Measurement precision
If manual calibration procedures are used, then measurement precision can be achieved, but productivity decreases due to labor-intensive calibration process
Solution Approach 1:
The calibration process utilizes the system's own operational components to perform self-calibration. The auger meters material into a collection container during normal operation, and the control system automatically calculates calibration factors based on measured discharge rates, eliminating the need for separate manual calibration procedures.
Solution Approach 2:
The control system incorporates feedback from sensors that measure the actual material discharge rate and compares it to the target rate. Based on this feedback, the system automatically adjusts operational parameters or records calibration factors to achieve precise metering without manual intervention.
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
Reduces costs by minimizing the need for full system replacement, simplifies calibration, and enhances operational efficiency by enabling quick module servicing and adjustment.
Implementation Method 1
rotating the meter rolls several turns (e.g., 10 to 15 turns) to discharge a large quantity of product
Implementation Method 2
An air stream through the air tubes is produced by a blower or fan typically supported on the air cart. The air stream carries the metered product through the air tubes
Data Source
AI summary
A method of calibrating a metering system having a plurality of meter modules. Each of the meter modules includes an auger in communication with a product, the auger is driven by an electric motor. The method includes loading the auger with the product, discharging a metered quantity of the product from the auger by actuating the electric motor to drive the auger at a predetermined rotational speed for a predetermined number of auger revolutions. The discharged metered quantity of the product is captured with the capture structure. A load cell generates a signal magnitude correlating a known mass to obtain a derived mass value. A controller calculates a mass per auger revolution (MPR) value. The MPR values of each of the plurality of meter modules is summed and stored in memory. A derived application rate is calculated and compared to the derived application rate.