Feed Mixer CVT Control for Variable Torque Mixing Loads
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Solution Overview
Problem
Conventional livestock feed mixers lack efficiency and speed in mixing feed materials due to varying physical characteristics and mixing conditions, leading to inefficient and slow mixing processes.
Innovation Solution
A control system for livestock feed mixers that utilizes a continuously variable transmission (CVT) with sensors and an electronic control unit to monitor mixing conditions and adjust the speed ratio based on parameters such as pressure, temperature, and torque to optimize mixing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional livestock feed mixers use external torque sources with fixed transmission ratios, then the structure is simple, but the mixing efficiency is low when feed materials are added or released causing abrupt changes in mixing conditions
Solution Approach 1:
The patent applies a continuously variable transmission (CVT) system that dynamically adjusts the transmission ratio based on real-time mixing conditions. The CVT allows continuous variation of the speed ratio between the power source and agitators, enabling the system to adapt to changing load conditions during feeding and discharge operations, thereby maintaining optimal mixing efficiency without fixed gear ratios.
Solution Approach 2:
The patent implements a feedback control system using sensors (torque sensor, pressure sensor, temperature sensor) that continuously monitor mixing conditions and transmit signals to the electronic control unit. The ECU processes these signals and adjusts the CVT transmission ratio accordingly, creating a closed-loop control system that responds to actual mixing state changes, thereby resolving the contradiction between simplicity and efficiency.
2Speed
If the mixing speed is increased to improve mixing efficiency, then the mixing time is reduced, but the torque requirements increase during loading and unloading phases
Solution Approach 1:
The CVT system enables dynamic adjustment of the transmission ratio to match the instantaneous torque requirements. During loading and unloading phases when torque demands spike, the CVT automatically increases the transmission ratio to provide higher torque to the agitators. During normal mixing operations, the transmission ratio is optimized for higher speeds, thereby decoupling the speed-torque trade-off and allowing both high speed and high torque as needed.
Solution Approach 2:
The patent changes the transmission ratio parameter continuously based on operating conditions. By varying this key parameter, the system can optimize the balance between speed and torque in real-time, allowing high agitator speeds during stable mixing while providing high torque during transient loading/unloading phases, thus resolving the speed-torque contradiction.
3Adaptability or versatility
If fixed transmission ratios are used to simplify the system, then the device complexity is low, but the system cannot adapt to varying physical characteristics of feed materials and mixing conditions
Solution Approach 1:
The patent employs multiple sensors (torque sensor on the driveline, pressure sensor in the hydrostatic loop, temperature sensor) that provide continuous feedback about mixing conditions to the electronic control unit. This feedback mechanism enables the system to detect changes in feed material characteristics and mixing state, automatically adjusting the CVT transmission ratio to adapt to varying conditions without requiring complex mechanical reconfiguration.
Solution Approach 2:
The patent replaces traditional mechanical transmission systems with fixed gear ratios with a hydrostatic CVT system controlled by electronic signals. This substitution allows for continuous, smooth variation of the transmission ratio through hydraulic control rather than discrete mechanical gear changes, providing superior adaptability to varying mixing conditions while keeping the overall system architecture manageable through electronic control.
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 enhances mixing efficiency by dynamically adjusting the speed and torque to match changing conditions, ensuring consistent and rapid mixing of feed materials.
Implementation Method 1
a continuously variable transmission that connects the driveline and the power source and having a hydrostatic loop to provide a speed ratio between the input speed and the output speed
Data Source
AI summary
A control system for mixing materials for livestock feed including a container that receives the materials, agitators that mix the materials in the container, a driveline that drives the agitators at an output speed with an output torque, a power source that provides an input speed at an input torque, a continuously variable transmission that connects the driveline and the power source and having a hydrostatic loop to provide a speed ratio between the input speed and the output speed, a plurality of sensors positioned between the power source and the agitators that provides mixing signals commensurate to mixing parameters, and an electronic control unit configured to receive the mixing signals, extract mixing parameter values from the mixing signals, and actuate the continuously variable transmission and adjust the speed ratio based on the mixing parameter values to enhance efficiency of the mixing of the materials.