Livestock Feed Mixer CVT Torque Control Under Heavy Load
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Solution Overview
Problem
Conventional livestock feed mixers often face power management issues, where the torque demand exceeds the power source's capacity when handling large quantities of feed materials, leading to abrupt mixing cessation.
Innovation Solution
A control system utilizing a continuously variable transmission and an electronic control unit to adjust the speed ratio between the power source and the mixer, ensuring a linear relationship between input and output torque, thereby extending the power source's capacity and preventing overload.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If more feed materials are added to the mixer, then the mixing capacity and productivity are improved, but the torque demand quickly reaches and exceeds the power source limit, causing mixing to stop
Solution Approach 1:
The patent implements dynamic speed ratio adjustment through a continuously variable transmission (CVT) system. The electronic control unit continuously monitors torque demand and adjusts the speed ratio in real-time, allowing the system to adapt to changing load conditions as feed materials are added, thereby maintaining continuous operation without exceeding power source limits
Solution Approach 2:
The system changes the operational parameters by adjusting the speed ratio between input and output shafts. By modifying this parameter dynamically, the system can deliver appropriate torque levels to match the power source capacity while maintaining productivity, preventing the torque demand from exceeding the power source limit
2Reliability
If the speed ratio is adjusted to extend power source capacity, then the torque control precision is improved, but the device complexity increases due to the continuously variable transmission and electronic control system
Solution Approach 1:
The electronic control unit implements a feedback mechanism by continuously monitoring the torque demand through torque sensors and adjusting the speed ratio accordingly. This closed-loop control ensures precise torque management while automating the complex adjustments, reducing the operational burden despite increased system complexity
Solution Approach 2:
The continuously variable transmission acts as an intermediary between the power source and the mixing mechanism. It provides a buffer that allows smooth torque adjustment, protecting the power source from overload while maintaining the required mixing torque, thus managing the complexity through a dedicated intermediate system
3Device complexity
If conventional mixers operate without torque control, then the device complexity is reduced, but the power source is quickly overcome when handling large quantities of feed materials
Solution Approach 1:
The system implements self-service through automated electronic control that monitors torque demand and adjusts the speed ratio without external intervention. The electronic control unit automatically manages the torque control based on real-time conditions, allowing the system to maintain optimal performance independently, thus justifying the added complexity through autonomous operation
Data Source
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Figure 1C
AI summary
A control system (A-1000) for mixing materials (100) having a container (B-1100) to receive the materials (100), agitators (B-1300), a driveline (B-1200) to drive the agitators at an output speed with an output torque (Tout), an power source (C-1000) to provide an input speed with an input torque (Tin), a continuously variable transmission (A-1500) that connects the driveline and the power source, and an electronic control unit (A-1100) configured to adjust a speed ratio of the continuously variable transmission to provide a linear relationship between the input torque and the output torque with a slope (M), when the input torque is below a control input threshold (Tin_control), and to follow a corrected linear relationship between the input torque and the output torque with a corrected slope (Mc) smaller than the slope when the input torque is above the control input threshold.