Fodder Mixing Wagon Sensor Head Positioning for Real-Time Mixture Analysis
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Solution Overview
Problem
Existing fodder mixing wagons require separate analysis of each fodder component before mixing, which is inefficient and does not allow for real-time control of the mixing process, limiting the ability to determine fodder values in the mixture during mixing.
Innovation Solution
A sensor system with a pick-up head operable within the mixing container determines fodder values of all components in the mixture, allowing for continuous monitoring and control of the loading and mixing processes, using NIR sensors or other technologies to assess mixing accuracy and adjust accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the sensor head is arranged in the loading unit to determine fodder values of individual components, then the loading process can be controlled, but the fodder values of the mixture cannot be determined during mixing
Solution Approach 1:
The sensor head is moved from the loading unit to the interior of the mixing container, changing the spatial dimension of measurement. This allows the sensor to directly contact and analyze the fodder mixture during mixing, enabling real-time determination of mixture composition and nutritional values that was previously impossible with loading-unit-only sensors.
Solution Approach 2:
The sensor head acts as an intermediary between the fodder mixture and the control system. By positioning it inside the mixing container, it directly measures the mixture's properties and transmits this information to the control system, enabling closed-loop control of both loading and mixing processes based on actual mixture composition.
2Loss of information
If separate analysis of each fodder component is performed before mixing, then individual component values are known, but the mixing process cannot be controlled in real-time
Solution Approach 1:
The sensor head continuously measures fodder values during both loading and mixing operations, providing uninterrupted information about the mixture composition. This continuous measurement enables real-time adjustments to be made, eliminating the need to wait until mixing is complete to assess the final mixture quality.
Solution Approach 2:
The control system uses real-time sensor data from the mixing container to adjust the loading and mixing processes. The sensor continuously provides feedback on mixture composition, allowing the control system to optimize ingredient addition and mixing parameters dynamically, thereby improving both information availability and process efficiency.
3Device complexity
If the sensor head is placed outside the mixing container, then the structure is simpler, but contact-free scanning cannot provide accurate mixture composition data
Solution Approach 1:
The sensor system is segmented into a stationary mounting structure and a rotating sensor head. The sensor head is positioned to rotate with the mixing device, allowing it to sequentially contact different portions of the mixture while the stationary part maintains structural support and connections. This segmentation enables accurate measurement while maintaining structural integrity.
Solution Approach 2:
The sensor head is designed to rotate dynamically with the mixing device, matching the mixing container's rotation. This dynamic positioning ensures the sensor continuously contacts fresh portions of the mixture during mixing, providing accurate real-time composition data while the rotating mechanism keeps the sensor structure relatively simple compared to a complex articulated arm system.
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 efficient control of the loading and mixing processes by providing real-time fodder value data, ensuring accurate mixing and optimizing the composition of the final fodder mixture without the need for pre-analysis of individual components.
Implementation Method 1
the sensor records e.g. NIR light waves reflected by the fodder components and evaluates them spectroscopically (near infrared)
Data Source
AI summary
A fodder mixing wagon, comprising a mixing container containing a mixing device, which is adapted to be driven in a mixing process of at least two fodder components, and at least one electronically operable sensor system having a head and used for determining fodder values of at least one fodder component, the head is arranged such that it is operable in the interior of the fodder mixture during the mixing process for determining fodder values of all loaded fodder components and/or the mixing accuracy of the fodder mixture.