Bulk Material Filling Apparatus with Optical Level Detection
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Solution Overview
Problem
Existing filling apparatuses for bulk materials, such as sand, are time-consuming, physically demanding, and prone to dust formation, with unreliable automatic shutdown mechanisms, posing health and safety risks.
Innovation Solution
An electro-optical distance measuring device with a light guide is integrated into the filling apparatus, connected to a control device, and a suction-removal nozzle is arranged coaxially around the blow-out lance to accurately measure the fill level and prevent dust escape, enabling reliable automatic shutdown and efficient dust management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual or semi-automatic filling is used, then the filling process can be performed without advanced measurement devices, but the filling is time-consuming and physically stressful
Solution Approach 1:
The system performs automatic filling control through self-monitoring of the fill level via electro-optical sensors and automated shutdown, eliminating the need for continuous manual monitoring and reducing physical stress on personnel while maintaining high productivity
Solution Approach 2:
Manual filling operations are replaced by an automated pneumatic conveying system with electronic control, where electro-optical distance measuring devices monitor fill level and trigger automatic shutdown, converting manual labor into an automated mechanical-electronic system
2Extent of automation
If counterpressure measurement is used for automatic shutdown, then some automation is achieved, but the control is unreliable due to low counterpressure values
Solution Approach 1:
The unreliable mechanical counterpressure measurement is replaced by an electro-optical distance measuring system that uses light propagation time to directly measure fill level, providing reliable automatic shutdown control through optical rather than mechanical sensing
Solution Approach 2:
The measurement parameter is changed from indirect counterpressure measurement (in the region of a few millibars) to direct optical distance measurement, fundamentally changing the physical quantity being measured to achieve reliable fill level detection and automatic shutdown
3Measurement precision
If the blow-out lance projects into the filling opening, then direct fill level measurement is possible, but dust may escape into the atmosphere
Solution Approach 1:
A suction-removal nozzle is introduced as an intermediary component between the blow-out lance and the environment, capturing dust particles that escape during filling and preventing their release into the atmosphere, thus resolving the conflict between measurement accessibility and dust containment
Solution Approach 2:
The dust that would normally escape harmfully is converted into a controllable flow by the suction-removal nozzle, which actively captures and removes dust particles, transforming the harmful dust escape into a controlled dust removal process that protects the environment and personnel
4Measurement precision
If electro-optical distance measuring device with light guide is used, then accurate fill level measurement is achieved, but device complexity increases
Solution Approach 1:
The electro-optical distance measuring device is extracted as a separate, modular component with its own light guide, allowing it to be positioned independently at the blow-out lance while maintaining accurate fill level measurement, thus managing complexity through modular design
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 solution ensures precise fill level detection, automatic shutdown, and reduced dust exposure, enhancing safety and efficiency by preventing overfilling and leakage, thus minimizing the need for protective gear and optimizing the filling process.
Implementation Method 1
an electro-optical distance measuring device connected to the control device and having a light guide is provided for measuring the fill level of the bulk material in the container during the filling process
Implementation Method 2
an electro-optical distance measuring device... which is used to measure a distance via the propagation time measurement of a temporally short light pulse which is emitted via a light guide, reflected at a target and received again by the same light guide
Implementation Method 3
a suction-removal nozzle is arranged on the blow-out lance coaxially around the blow-out lance, wherein the free end of the light guide of the electro-optical distance measuring device is arranged on the suction-removal nozzle in the region of the blow-out lance. Any dust which may arise can be sucked off during the filling process
Data Source
AI summary
The invention relates to an apparatus for filling a container with bulk material, having a storage container for the bulk material with a closable lid and an outlet, a metering device arranged below the storage container, a pneumatic conveying device for conveying the bulk material with the aid of compressed air into the container to be filled via a conveying hose with a blow-out lance at the free end, wherein a control device for controlling the filling process is provided. In order to be able to ensure that the filling process is terminated on time, an electro-optical distance-measuring device which is connected to the control device is arranged with a light guide for measuring the filling level of the bulk material in the container during the filling process, and a suction-removal nozzle is arranged coaxially around the blow-out lance at the blow-out lance, wherein the free end of the light guide of the electro-optical distance measuring device is arranged at the region of the blow-out lance on the suction-removal nozzle.