Conveyor Belt Speed Control via Encoder Feedback

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Solution Overview

Problem

Existing systems for delivering materials onto conveyor belts often result in overflow, inaccurate control of discharge rate, and cumbersome operation, leading to inefficiencies and unwanted consequences in industries like hydrocarbon exploration and production.

Innovation Solution

A material discharge metering system that includes an electronic controller, encoder, and weighing device to measure and control the speed of the conveyor belt, ensuring accurate and efficient delivery of materials by adjusting the motor speed based on measured speed and weight data.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If material is dispensed onto the conveyor belt without speed control, then the material delivery process is simple, but material overflows off the sides of the conveyor and discharge rate cannot be controlled

Engineering Contradiction:

Improvedischarge rate controlVSAvoidsystem complexity

Core Design Contradiction:

Quantity of substanceVSDevice complexity

Solution Approach 1:

The patent implements a feedback control system where an encoder measures the actual conveyor belt speed and feeds this information back to the controller. The controller compares the measured speed with the desired speed and adjusts the motor output accordingly, enabling precise control of material discharge rate while preventing overflow.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces manual mechanical speed control with an automated electronic control system. Instead of manually adjusting mechanical components to control conveyor speed and material discharge, the system uses electronic sensors (encoder), controllers, and motor control to automatically regulate the discharge rate based on measured parameters.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If conveyor speed is increased to improve material delivery rate, then productivity increases, but material overflows and control accuracy decreases

Engineering Contradiction:

Improvematerial delivery rateVSAvoiddischarge rate control accuracy

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The encoder provides continuous feedback on the actual conveyor belt speed, allowing the controller to maintain precise control of the material delivery rate even at high speeds. The feedback loop ensures that the discharge rate remains accurate by continuously comparing actual speed with target speed and making real-time adjustments.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system dynamically adjusts the conveyor belt speed based on real-time conditions and material flow requirements. Rather than operating at a fixed speed, the controller can vary the speed within a range to optimize both productivity and control accuracy, adapting to changing operational demands.

Inventive Principle:

Principle #15Dynamics

3Ease of operation

If manual operation of discharge gates is used, then the system is simple to manufacture, but operation becomes cumbersome and inaccurate

Engineering Contradiction:

Improvedischarge control easeVSAvoiddischarge rate accuracy

Core Design Contradiction:

Ease of operationVSQuantity of substance

Solution Approach 1:

The system performs self-service by automatically controlling the discharge rate without requiring manual intervention. The controller autonomously adjusts the motor speed based on encoder feedback to maintain the desired material delivery rate, eliminating the need for operators to manually adjust discharge gates while improving both ease of operation and accuracy.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual mechanical gate operation with an automated electronic control system. Instead of operators physically adjusting discharge gates, the system uses electronic sensors and motor control to automatically regulate material flow, improving both operational ease and discharge rate accuracy.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Reliability

If conveyor speed is not monitored, then the system is simpler, but overflow prevention and discharge control become impossible

Engineering Contradiction:

Improveoverflow preventionVSAvoidspeed monitoring system

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The encoder provides continuous feedback on conveyor belt speed, enabling the controller to detect when the conveyor is approaching conditions that would cause overflow. The feedback loop allows the system to proactively adjust speed to prevent overflow before it occurs, ensuring reliable operation.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The speed monitoring system enables preliminary action by detecting changes in conveyor speed that precede overflow conditions. The controller can take corrective action in advance by adjusting the motor output to maintain optimal speed, preventing overflow before it happens rather than reacting after overflow occurs.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS10106332B2Apparatus and methods for assisting in varying the amount of material delivered from a conveyor

Publication Date: 2018.10.23 AMERICAN CEMENTING LLC

AI summary

Automatically adjusting the amount of material delivered by a conveyor belt includes measuring the speed of a drive pulley that drives the conveyor belt and determining the weight of material dispensed onto the conveyor belt from at least one material dispenser on a real-time, ongoing basis. Based at least in part upon such speed and weight measurements, an electronic controller repeatedly adjusts the speed of the conveyor belt by dictating the output of at least one motor that drives the drive pulley.