Horizontal Auger Pipe Flow Estimation Using Distance Sensors
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Solution Overview
Problem
Current methods for monitoring feed consumption in commercial livestock production are inaccurate and costly, leading to inefficiencies such as feed outages, non-uniform delivery schedules, and lack of real-time data for proactive adjustments.
Innovation Solution
A low-cost apparatus using range detection sensors and a control system to estimate the flow rate of fluent solid materials in horizontal pipes, incorporating a movable transportation element and data processing to calculate flow rates with high accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If load cells are used to monitor feed disappearance in the bin, then measurement accuracy is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces mechanical load cells with optical sensors (infrared or laser distance sensors) to measure feed level. The optical sensors detect the position of the feed surface by measuring the reflection or absorption of light, converting a mechanical measurement problem into an optical detection problem. This substitution eliminates the need for mechanical contact with the feed material while maintaining measurement capability.
Solution Approach 2:
The patent introduces an intermediary element (reflective tape or marker) attached to the feed surface or conveyor belt to enhance the optical signal. This intermediary reflects infrared light or laser beams back to the sensors, improving detection reliability without requiring direct mechanical contact. The intermediary acts as a mediator between the feed material and the optical sensing system.
2Device complexity
If historical data and approximation methods are used for feed consumption monitoring, then device complexity is reduced, but measurement precision and real-time capability deteriorate
Solution Approach 1:
The patent implements continuous real-time monitoring by positioning optical sensors along the conveyor path to continuously measure feed level and consumption. The system processes measurements continuously as feed moves through the conveyor, providing ongoing data rather than periodic or historical summaries. This continuous measurement approach enables real-time feed consumption tracking while keeping the system relatively simple.
Solution Approach 2:
The system uses the existing conveyor infrastructure and feed flow characteristics to enable self-measuring capability. The optical sensors leverage the natural movement of feed through the conveyor and the reflective properties of the feed surface itself (or simple markers) to generate measurement data without requiring additional active components or complex processing mechanisms.
3Measurement precision
If multiple sensors are used to improve measurement accuracy, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent divides the measurement task into segments by using multiple optical sensors positioned at different locations along the conveyor path. Each sensor measures feed level or position at its specific location, and the control system integrates these segmented measurements to calculate overall feed consumption and flow rate. This segmentation allows accurate measurement across the entire feed stream while using simple, individual sensor components.
Solution Approach 2:
The optical sensors serve multiple functions: they detect feed level, measure feed position on the conveyor, and provide data for flow rate calculation. The same sensor hardware is used for different measurement purposes by varying the measurement parameters and data processing approaches, reducing the need for specialized components for each measurement function.
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
Provides highly accurate, near real-time data on feed usage, reducing inefficiencies and enabling proactive adjustments in livestock production.
Implementation Method 1
a plurality of distance sensors mounted in an upper part of the pipe and arranged to detect the distance of the material in a lower part of the pipe from the distance sensors
Data Source
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AI summary
Apparatus is provided for estimating a flow rate of a fluent solid material in a generally horizontal pipe having a movable transportation element such as an auger in the pipe for transporting the material along the pipe including distance sensors mounted in the pipe in an upper part of the pipe and arranged to detect the distance of the material in a lower part of the pipe from the sensor. Another sensor is provided to detect the rate of movement of the transportation element for example by detecting the metal of the auger flight. The output from the sensors is fed to a control system for analyzing the output signals from the sensors over time to provide the estimate of flow rate. The sensors can be mounted in a pressurized enclosure to prevent escape of dust though openings for the sensors.