Feeder Bin Discharge Rate Control via Feedback
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Solution Overview
Problem
Existing systems for discharging dry mixes of polymeric materials from feeder bins lack precision and reliability due to unpredictable flow properties, which results in uncontrollable properties of the resultant fracturing gels, as they do not account for variations in packing, moisture content, or environment.
Innovation Solution
A system that includes a feeder bin with a discharge device and a control system that continuously monitors and adjusts the discharge rate based on weight measurements of the dry mix, using a calibration curve to maintain precise control over the discharge rate by adjusting the speed of the discharge device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a dry mix of polymeric material is fed from the feeder bin, then the environmental concerns caused by hydrocarbon carrier fluid are eliminated, but the flow properties become much less predictable due to variations in packing, moisture content, and amount of dry mix
Solution Approach 1:
The system continuously measures the actual discharge rate of the dry mix and feeds this information back to the control system, which automatically adjusts the screw speed to maintain the desired discharge rate despite variations in flow properties
Solution Approach 2:
The system dynamically changes the operational parameters (screw speed) based on real-time measurements of discharge rate, allowing adaptation to varying flow properties of the dry mix while maintaining precise control
2Extent of automation
If a metering screw or auger is used to discharge dry mix, then the discharge process can be automated, but the actual amount of dry mix discharged is not measured or controlled after initial calibration
Solution Approach 1:
A measurement system continuously monitors the actual discharge rate and provides feedback to the control system, which automatically adjusts the screw speed to maintain precise control over the discharge amount, eliminating the need for manual recalibration
Solution Approach 2:
The system replaces reliance on purely mechanical calibration with an automated control system that uses electrical sensors and motors to precisely control and adjust the discharge rate based on real-time measurements
3Manufacturing precision
If the screw or auger is calibrated for each dry mix, then the initial discharge rate can be set correctly, but no quality control exists during the discharging process to account for variations in flow properties
Solution Approach 1:
The continuous measurement and feedback system provides ongoing quality control during the discharge process, automatically detecting and correcting deviations from the desired discharge rate caused by variations in flow properties
Solution Approach 2:
The system maintains continuous monitoring and adjustment of the discharge rate throughout the entire discharge process, ensuring consistent quality control rather than relying solely on initial calibration
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
Enables precise control of the discharge rate of dry mixes, ensuring consistent properties of the fracturing gels produced, even with variations in the dry mix environment, thereby improving the reliability and precision of the gel production process.
Implementation Method 1
a measurement system that continually makes a measurement indicative of a weight of the discharged dry mix of material
Implementation Method 2
a control system that receives a feedback signal indicative of the weight of the discharged dry mix of material and automatically adjusts a speed of operation of the discharge device based on the feedback signal
Data Source
AI summary
A system for precisely controlling a discharge rate of a discharged product is provided that includes a feeder bin having an internal chamber; a product disposed in the internal chamber of the feeder bin; and a discharge device that receives a portion of the product and discharges it at a discharge rate from the feeder The system also includes a control system that continually monitors the discharge rate of the discharged product and automatically adjusts the discharge rate based on measurements of the product.