Conveyor Belt Scale Using Roller Generator for Weight Measurement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional conveyor belt scales face inaccuracies in weight measurement due to horizontal forces generated by the moving belt, and they are susceptible to damage from lightning strikes due to the reliance on voltage and signal wires for control electronics.
Innovation Solution
A conveyor belt scale system that includes a generator to convert mechanical energy from the belt movement into electrical energy, which is used to power load cells, eliminating the need for separate speed sensors and reducing the number of control electronics and wires, thereby minimizing the impact of horizontal forces and lightning strikes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional belt scales use load cells with voltage and signal wires for control electronics, then weight measurement can be performed, but the system becomes susceptible to damage from lightning strikes
Solution Approach 1:
The patent replaces the conventional electrical wiring system (voltage and signal wires) with a mechanical energy transmission system using a roller connected to the conveyor belt. The roller converts mechanical energy from belt movement into electrical energy through a generator, eliminating the need for vulnerable electrical connections and control electronics that are susceptible to lightning strikes.
Solution Approach 2:
The system uses the conveyor belt's own motion to generate the electrical energy needed for the load cells. The roller is mechanically connected to the moving belt, and as the belt moves, it drives the roller which generates electricity through electromagnetic induction. This self-powered approach eliminates external wiring and makes the system immune to lightning damage.
2Device complexity
If conventional belt scales rely on separate speed sensors and control electronics, then speed measurement is available, but the device complexity increases
Solution Approach 1:
The patent combines the speed sensing function and power generation function into a single integrated system. The roller that is mechanically connected to the conveyor belt serves dual purposes: it generates electrical power for the load cells and simultaneously provides speed information through the frequency of the generated AC signal. This eliminates the need for separate speed sensors and reduces device complexity.
Solution Approach 2:
The roller-generator assembly performs multiple functions simultaneously: it generates electrical power for the load cells, provides speed measurement through signal frequency, and eliminates the need for separate control electronics. This multi-functional design reduces the overall complexity of the belt scale system while maintaining all necessary measurement capabilities.
3Measurement precision
If load cells are positioned to measure weight on a moving belt, then weight measurement is obtained, but horizontal forces from belt movement cause measurement inaccuracies
Solution Approach 1:
The patent extracts the speed measurement function from the weight measurement system. By using the generator's output frequency to determine belt speed and calculating weight by dividing load cell output by frequency, the system separates the measurement of weight and speed into independent channels. This prevents horizontal forces from affecting the weight measurement, as the load cell only needs to measure vertical force while speed is derived from the generator signal.
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 provides accurate weight measurements independent of conveyor belt speed and reduces the risk of electrical damage from lightning, enhancing the reliability and precision of mass flow rate calculations.
Implementation Method 1
A generator may be included that receives mechanical energy arising from the movement of the conveyor belt and outputs an electrical energy that corresponds to a rate of movement of the conveyor belt
Implementation Method 2
A portion of the weighframe is often coupled to a strain gauge load sensors or load cell, where the strain gauge deforms proportionately to the load on the belt. The gauge's resistance varies as it deforms and by applying a voltage across the gauge, an electrical signal is generated
Data Source
AI summary
A scale may include a conveyor belt that carries a load, where the load has a weight. A generator is included that receives mechanical energy arising from movement of the conveyor belt and outputs electrical energy that corresponds to a rate of movement of the conveyor belt. At least one load cell receives the electrical energy from the generator, senses the weight of the load, and outputs a voltage that corresponds to the weight of the load and the rate of movement of the conveyor belt.