Bulk Material Sensing System with Flow Member and Electromagnetic Sensor
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Solution Overview
Problem
Conventional sensing systems are unable to effectively monitor the flow of compressed bulk materials like grain, which is crucial for maintaining quality and preventing spoilage during the grain drying process.
Innovation Solution
A sensing system comprising a sensor assembly with a flow member and an electromagnetic sensor that detects parameters such as movement and rotational speed of the flow member, communicating with a controller to determine desired outputs like flow rate, enhancing durability, accuracy, and manufacturability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional sensing systems are used to monitor material flow, then the system structure is simple, but the system cannot effectively monitor compressed bulk materials like grain
Solution Approach 1:
The patent introduces a flow member as an intermediary element that directly contacts the compressed bulk material and translates its movement into detectable signals. The flow member includes sensing elements that interact with the material flow, allowing indirect measurement of material properties without requiring the sensor to directly penetrate or contact the compressed bulk material, thus enabling monitoring capability while maintaining reasonable system complexity
Solution Approach 2:
The patent replaces conventional mechanical sensing approaches with electromagnetic sensors that detect changes in electromagnetic fields caused by material flow. This substitution allows for non-contact or minimal-contact detection of bulk material flow, enabling the system to handle compressed materials like grain without the mechanical complexity of direct mechanical sensors
2Productivity
If grain flow speed is increased to improve productivity, then the drying efficiency increases, but the grain may not reach desired moisture content and may become over-dried
Solution Approach 1:
The patent implements a feedback control system where the electromagnetic sensor continuously monitors grain flow rate and provides real-time data to a controller. The controller adjusts drying parameters based on the measured flow rate, ensuring that even at high productivity levels, the grain remains in the dryer long enough to reach the desired moisture content without over-drying
Solution Approach 2:
The patent employs dynamic adjustment of sensing element positions and detection parameters based on varying grain flow conditions. The system can adapt its measurement strategy to different flow rates, maintaining high measurement precision whether the grain flow is slow or fast, thus enabling both high productivity and accurate monitoring
3Reliability
If the sensing element is made from metal material to enhance durability, then the sensor assembly becomes more robust, but the electromagnetic field detection may be affected
Solution Approach 1:
The patent applies different material properties to different parts of the sensing system. The flow member structure uses metal materials for durability and mechanical strength where needed, while the electromagnetic sensor components use non-conductive or electromagnetic-transparent materials in the detection zones to maintain field detection accuracy. This localized differentiation of material properties allows both durability and measurement precision to be optimized in their respective locations
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 accurately monitors grain flow, preventing over-drying and stress cracks, ensuring optimal moisture content and quality retention, thereby improving the grain drying process.
Implementation Method 1
the electromagnetic sensor is configured to detect at least one parameter of at least one of the flow member and a material flowing at least one of over and adjacent the sensor assembly
Data Source
AI summary
A sensing system for a bulk material includes a housing, a sensor assembly at least partially disposed in the housing, and a controller in communication with the sensor assembly. The sensor assembly includes a flow member and an electromagnetic sensor configured to detect at least one parameter of the flow member. The controller is configured to determine at least one desired output based upon the at least one parameter of the flow member.