Combination Scale Recalculation for Discharge Weight Changes
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Solution Overview
Problem
Semiautomatic combination scales suffer from weighing errors due to accidental addition or removal of items during discharge, leading to incorrect item combinations being transported together, which can result in packaging errors.
Innovation Solution
A combination scale with weighing conveyers, weight sensors, and a controller that executes combinatorial computations to select and manage discharge-target conveyers, re-executes computations for weight changes, and adjusts conveyer operations to prevent errors by reversing or halting conveyer direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If semiautomatic combination scales are used to allow manual supply of items, then flexibility in handling difficult-to-automate items is improved, but weighing errors occur due to accidental addition or removal of items during discharge
Solution Approach 1:
The system performs preliminary combinatorial computations to determine the optimal combination of items before discharge begins. Weight sensors measure items as they are supplied to weighing hoppers, and the controller calculates combinations in advance to ensure the total weight falls within the predetermined range, preventing weighing errors before they occur.
Solution Approach 2:
The system continuously monitors weight changes in weighing hoppers during the discharge process using weight sensors. When a weight change is detected (indicating accidental addition or removal of items), the controller receives feedback and responds by pausing the discharge, alerting the operator, and requiring re-computation of the combination to maintain weighing accuracy.
2Reliability
If combinatorial computations are repeatedly executed to prevent weighing errors, then weighing accuracy is improved, but processing time increases
Solution Approach 1:
The system performs combinatorial computations in advance before items are discharged, determining the optimal combination while items are being supplied to weighing hoppers. This preliminary calculation prevents the need for repeated computations during discharge, reducing processing time while maintaining weighing accuracy.
Solution Approach 2:
The system automatically detects weight changes using weight sensors and triggers re-computations only when necessary, rather than continuously recalculating. This self-monitoring approach minimizes unnecessary processing time while ensuring weighing accuracy is maintained through targeted re-computations only when actual changes occur.
3Ease of operation
If manual supply of items to weighing hoppers is allowed, then ease of operation for various item types is improved, but weighing errors occur due to operator mistakes
Solution Approach 1:
Weight sensors continuously monitor the weight of items in weighing hoppers and provide feedback to the controller. When a weight change is detected during the discharge process, the system immediately responds by pausing discharge and alerting the operator, preventing weighing errors caused by accidental addition or removal of items while maintaining ease of manual operation.
Solution Approach 2:
The system performs preliminary combinatorial computations to determine the correct combination of items before discharge begins. By calculating the optimal combination in advance and comparing actual weights against expected weights, the system prevents weighing errors before they affect the discharged items, while allowing operators to manually supply items easily.
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
Prevents weighing errors by ensuring only items within a predetermined weight range are transported, reducing the risk of incorrect item combinations reaching subsequent apparatuses.
Implementation Method 1
a plurality of weight sensors disposed correspondingly to the plurality of weighing conveyers to measure weights of the items in the plurality of weighing conveyers
Data Source
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AI summary
For any weight change of items in a combination of discharge-target weighing conveyers selected by combinatorial computations during a standby state before the conveyers start to be driven, the combinatorial computations are executed again to select a new combination of discharge-target weighing conveyers, so that the items on the selected weighing conveyers that changed in weight are not transported to a collection conveyer without being possibly reselected into the new combination of conveyers. For any weight change of the items in the combination of discharge-target weighing conveyers during a transport-active state after the conveyers start to be driven, at least one of the collection conveyer or the weighing conveyer subject to the weight change is no longer driven or driven in an opposite transport direction, so that the items on the selected weighing conveyers that changed in weight are not transported into a packaging machine subsequent to the collection conveyer.