Conveyor Capacity Control for Granular Material
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conveyors used in agricultural operations often operate below their maximum capacity due to manual control of discharge flow rates, leading to increased unproductive downtime during seeding and harvesting, especially when handling granular materials from vehicles with non-standard discharge openings like belly dump trailers.
Innovation Solution
A conveyor capacity control system that includes a flow rate control processor, sensors, and automated gate control to adjust the discharge flow rate to match the maximum conveyor flow rate, ensuring efficient operation by detecting and adjusting the flow rate to prevent material buildup or overflow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual control of discharge gate is used, then operator can visually monitor and adjust flow rate, but conveyor operates below maximum capacity increasing downtime
Solution Approach 1:
The system uses flow sensors to continuously monitor the actual discharge flow rate and feeds this information back to the control processor. The processor compares the measured flow rate with the target flow rate (conveyor maximum capacity) and automatically adjusts the discharge gate position to eliminate any deviation, ensuring the conveyor operates at maximum capacity throughout the transfer process.
Solution Approach 2:
The patent replaces manual mechanical control of the discharge gate with an automated control system that uses electronic sensors, a control processor, and an actuator mechanism. This substitution eliminates the need for manual visual monitoring and manual gate adjustment, enabling precise automated control that maintains optimal flow rates and maximizes conveyor capacity utilization.
2Productivity
If discharge flow rate is increased to match conveyor capacity, then productivity improves, but material may build up and overflow the hopper
Solution Approach 1:
The control system continuously monitors the actual discharge flow rate using flow sensors and compares it with the target flow rate. This feedback mechanism allows the system to automatically adjust the discharge gate to maintain the optimal flow rate that matches conveyor capacity without exceeding it, preventing material buildup and overflow while maximizing productivity.
Solution Approach 2:
The system dynamically adjusts the discharge gate position parameter based on real-time flow conditions to optimize the discharge flow rate. By changing the gate opening parameter, the system achieves the maximum safe flow rate that matches conveyor capacity without causing material overflow, thus resolving the contradiction between productivity and overflow prevention.
3Reliability
If discharge flow rate is decreased to prevent overflow, then material buildup is avoided, but conveyor operates below capacity increasing downtime
Solution Approach 1:
The automated control system with flow sensors provides continuous feedback on the actual discharge flow rate, enabling precise control that prevents overflow while maintaining maximum productivity. The system adjusts the discharge gate to achieve the optimal flow rate that matches conveyor capacity, eliminating the need to operate below capacity and thus resolving the contradiction between reliability and productivity.
Solution Approach 2:
The control system automatically monitors and adjusts the discharge flow rate without requiring manual intervention. The processor receives flow rate information from sensors, compares it with the target rate, and self-adjusts the discharge gate position to maintain optimal operation, ensuring both overflow prevention and maximum conveyor capacity utilization simultaneously.
4Productivity
If automated flow rate control is implemented, then conveyor operates at maximum capacity, but system complexity increases
Solution Approach 1:
The system implements feedback control using flow sensors and a control processor that automatically adjusts the discharge gate based on measured flow rates. This feedback mechanism enables the conveyor to operate at maximum capacity with minimal manual intervention, and the automated nature of the control reduces the need for complex manual monitoring and adjustment procedures, thereby managing system complexity while maximizing productivity.
Solution Approach 2:
The patent replaces complex manual control procedures with an automated electronic control system that uses sensors and processors. This substitution simplifies the overall control approach by using electronic automation rather than manual mechanical adjustment, reducing the complexity of operational procedures while enabling precise control that maintains maximum conveyor capacity utilization.
Data Source
AI summary
A conveyor capacity control system includes a conveyor operative to receive granular material at a conveyor intake thereof and convey same to a conveyor discharge with a conveying device at a conveyor flow rate up to a maximum conveyor flow rate, and a granular material container with a container discharge opening oriented to discharge granular material from the granular material container into the conveyor intake, and a discharge gate movable to control a size of the container discharge opening. A flow rate control processor is operative to determine the maximum conveyor flow rate and detect when a discharge flow rate of granular material from the container discharge opening into the conveyor intake is greater than or less than the maximum conveyor flow rate, and increase or decrease the discharge flow rate to substantially coincide with the maximum conveyor flow rate. A hoist control is also provided for a truck box.