Flexure Plate Load Sensing for Conveyor Accuracy
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Solution Overview
Problem
Conventional load sensing systems for conveyor belts, particularly single point load cells, face challenges in accurately measuring light loads due to insensitivity to moments generated by off-center loading and horizontal forces like drag, which compromise their effectiveness, especially when rigidly secured to other structures.
Innovation Solution
A load sensing system featuring a flexure plate with an upper and lower region and at least one flex region, allowing only lateral movement, combined with a load cell and bracket configuration that suspends the flexure plate to enable lateral movement during deflection, thereby maintaining sensitivity to light loads and minimizing tilting and moment effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If single point load cells are rigidly secured to other structures, then structural robustness is improved, but measurement precision deteriorates due to compromised deflection and moment effects
Solution Approach 1:
The system divides the support structure into multiple load sensing assemblies, each independently supporting a weigh idler. This segmentation allows each assembly to deflect independently, maintaining measurement precision while providing overall structural robustness through the distributed configuration.
Solution Approach 2:
The patent changes the mechanical parameters of the load sensing assemblies by allowing controlled deflection and rotation. The weigh idlers are designed to deflect vertically and rotate horizontally, transforming the rigid connection into a flexible one that maintains both structural integrity and measurement accuracy.
2Stability of the object's composition
If weigh idlers are rigidly secured to load cells, then structural stability is improved, but sensitivity to light loads deteriorates due to impeded deflection
Solution Approach 1:
The system transitions from a static rigid connection to a dynamic flexible connection. The load sensing assemblies are designed to deflect and rotate in response to applied loads, with the flexibility calibrated to maintain structural stability while preserving sensitivity to light loads through controlled dynamic response.
3Strength
If load cells are constrained to prevent tilting, then structural robustness is improved, but insensitivity to off-center loading deteriorates
Solution Approach 1:
The system uses multiple segmented load sensing assemblies distributed along the conveyor, each capable of independent tilting. This segmentation allows the system to maintain overall structural robustness while each segment accommodates off-center loads through localized tilting, preserving insensitivity to load position.
4Strength
If weigh platforms are externally coupled to structures, then structural support is improved, but effectiveness of built-in compensation deteriorates
Solution Approach 1:
The patent introduces flexible coupling elements as intermediaries between the weigh platforms and external support structures. These intermediaries transmit necessary structural support while isolating the compensation mechanisms from external constraints, preserving the effectiveness of built-in compensation for light load measurement.
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 achieves improved accuracy and insensitivity to light loads on conveyor belts by allowing limited freedom of movement, reducing the impact of horizontal forces and maintaining consistent sensitivity to load position, even under off-center loading conditions.
Implementation Method 1
a flexure plate with an upper region extending along a longitudinal length of the flexure plate, a lower region disposed below the upper region, and at least one flex region disposed between the upper region and the lower region
Data Source
AI summary
A load sensing system having at least one load sensing assembly, each assembly including a flexure plate with an upper region extending along a longitudinal length of the flexure plate, a lower region disposed below the upper region, and at least one flex region disposed between the upper region and the lower region. The lower region defines a mounting feature for an end of a weigh idler and is capable of substantially only lateral movement relative to the upper region. Each assembly further includes a load cell and a bracket having a first end rigidly connected to a force transmission surface of the load cell and having a second end rigidly connected at a plurality of areas to the upper region of the flexure plate to rigidly capture the upper region while suspending the remainder of the flexure plate.