Bulk Material Container Monitoring via Motor Current and Level Sensors
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Solution Overview
Problem
Current monitoring and control systems for bulk material containers are inadequate in providing real-time, accurate, and safe monitoring of material levels and environment conditions, particularly failing to account for non-uniform surface shapes and top crusting issues, which leads to inefficiencies and increased costs due to manual inspections and reliance on additional machinery for weight-based measurements.
Innovation Solution
A comprehensive monitoring and control system utilizing a set of sensors connected to a material container and conveyance motor, including a level sensor and motor sensor, that provides real-time data on material volume, flow rate, and environmental conditions, with a central server for data analysis and alerting, enabling remote access and automatic adjustments to optimize operations and prevent top crusting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual monitoring procedures are used to check material volume and environment conditions, then operational flexibility is maintained, but safety risks increase and productivity decreases due to the need for personnel entry into storage containers
Solution Approach 1:
The patent replaces manual mechanical inspection with an automated sensor-based monitoring system. Sensors continuously measure material volume, temperature, humidity, and other parameters, eliminating the need for personnel to physically enter storage containers while providing real-time data for operational decision-making.
Solution Approach 2:
The system enables self-monitoring of storage containers through automated sensors and processing units that continuously track material conditions without human intervention. The system serves itself by automatically detecting, recording, and reporting material volume and environment conditions, freeing personnel from routine inspection tasks.
2Measurement precision
If direct measurement systems using weight monitoring are implemented to calculate material volume, then measurement accuracy is improved, but device complexity and cost increase due to additional machinery requirements
Solution Approach 1:
The patent employs sensors that serve multiple functions: they monitor material volume, track environment conditions (temperature, humidity), and detect material characteristics. This multi-functionality eliminates the need for separate weight-based measurement systems while maintaining measurement accuracy through alternative sensing methods.
Solution Approach 2:
The system replaces mechanical weight-based measurement with non-contact or minimal-contact sensing technologies. Sensors use electromagnetic, optical, or acoustic fields to measure material properties, eliminating the need for complex weighing machinery while achieving comparable or superior measurement precision.
3Extent of automation
If single-point or multi-point sensing systems are used to monitor material levels, then automation is improved, but measurement accuracy deteriorates when materials do not maintain uniform surface shapes or develop top crusting
Solution Approach 1:
The patent divides the monitoring function into multiple sensing points distributed throughout the storage container. Instead of relying on a single measurement location, the system uses multiple sensors at different positions and depths to capture the true three-dimensional state of the material, accurately measuring volume even when the surface is non-uniform or crusted.
Solution Approach 2:
The system transitions from two-dimensional surface-level monitoring to three-dimensional volumetric measurement. Sensors are positioned at various depths and locations to map the complete volume of material, allowing accurate measurement regardless of surface shape irregularities or top crusting conditions that would fool single-point surface sensors.
Data Source
AI summary
A material container monitoring and management system comprising sensors operatively connected to a central local processor in wireless communication with a central server. The sensor set at least includes a material level sensor and a motor current sensor which respectively monitor a material level within the container and a motor current draw. Sensor data is relayed to the local processor to provide where it is initially analyzed and subsequently relayed to the central server for improved bin monitoring, alerting and control based on material level, current draw and detected environmental conditions. Given the environmental conditions available, the system operation parameters can be automatically or manually adjusted while dynamic performance benchmarks update relative to the measured variables and predicted dispensing patterns based on historical data. User monitoring comprises various selectable geographical views of containers and drill down view include specific information related to that container.