Distributor Disk Geometry for Disc Spreader Mass Flow Control
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Solution Overview
Problem
Existing disc spreaders face challenges in accurately controlling and measuring small mass flows of grit at narrow spreading or working widths, leading to reduced measurement accuracy and uneven distribution of spreading materials.
Innovation Solution
The method involves selecting a distributor disk with a geometry factor of at least 0.1 Nm/(kg/min) at 900 rpm, featuring a maximum throw angle of 5° and a flight circle diameter of at least 60 cm, and storing functional relationships between torque and mass flow in the control device to enhance sensitivity and accuracy of mass flow control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a standard distributor disk is used for narrow spreading widths, then the device can operate at small working widths, but the torque becomes too small for accurate sensor detection
Solution Approach 1:
The patent changes the geometric parameters of the distributor disk by providing multiple disks with different geometry factors. Each disk is optimized for specific spreading width ranges, with geometry factors between 0.08 and 0.15 Nm/(kg/min) at 900 rpm. This allows maintaining adequate torque levels even at narrow spreading widths where standard disks would produce insufficient torque for accurate sensor detection.
2Measurement precision
If the distributor disk geometry is optimized for narrow widths, then torque detection sensitivity improves, but the disk cannot be used for wider spreading widths
Solution Approach 1:
The patent segments the distributor disk functionality by providing multiple disks with different geometry factors optimized for specific spreading width ranges. The control device includes a memory with functional relationships stored for each disk type, allowing the system to select and switch between appropriate disks based on the desired working width, thereby maintaining both sensitivity and versatility.
3Measurement precision
If multiple distributor disks with different geometry factors are provided, then accuracy across different working widths is maintained, but the device complexity increases
Solution Approach 1:
The patent achieves universality by designing a modular system where multiple distributor disks with different geometry factors can be interchanged on the same mounting location. The control device is programmed with functional relationships for each disk type and automatically selects the appropriate disk based on the desired spreading width, allowing one control system to manage multiple disk configurations without requiring separate control systems for each disk type.
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
This approach ensures sufficient torque detection for accurate mass flow regulation even at very small target mass flows, achieving high sensitivity and uniform distribution of spreading materials across small working widths.
Implementation Method 1
the torque representative of the actual mass flow of at least one shaft in a drive train of the distributor disk being determined by sensors
Data Source
Figure 1~2
AI summary
A method for controlling the actual mass flow rate of spreading material of an adjustable metering unit of a disc spreader with a distributor disc associated with the metering unit is proposed, wherein a target mass flow rate of spreading material is input to a control device as a reference variable and the torque of a shaft in the drive train of the distributor disc, representative of the actual mass flow rate, is sensorily determined and transmitted to the control device as the controlled variable, whereupon the deviation of the actual mass flow rate from the target mass flow rate is determined and a manipulated variable representative of the opening position of the metering unit is generated in order to adjust the metering unit to the target mass flow rate.A storage device associated with the control unit contains several functional relationships between the torque of different distributor discs and the mass flow of spreading material impacting each distributor disc at a given rotational speed. Each relationship takes into account a geometric factor of the respective distributor disc. The appropriate functional relationship is selected based on information representative of the respective distributor disc, which is transmitted to the control unit. The selection of a distributor disc is based on a suitable spreading or working width for that specific distributor disc.To increase the sensitivity of the mass flow control at small working widths, the invention provides that, for a small spreading width of less than 38 m or for a small working width of less than 18 m, a distribution disc is selected which has a geometry factor of at least 0.1 (Nm)/(kg/min) at a rotational speed of 900 rpm, defined by the quotient of its torque divided by the mass flow of material impinging on this distribution disc during operation. The invention further relates to a disc spreader suitable for carrying out such a method and to the use of a distribution disc set for this spreader.