Automated Follower Plate Removal via Force-Feedback Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manual alternation between lifting and ventilation modes to remove a follower plate from a container is difficult and requires operator expertise, leading to inefficiencies in the process of replacing containers filled with viscous materials.
Innovation Solution
Implementing a method where the switch-over between lifting and ventilation modes is automated by continuously measuring characteristic variables such as force or position using sensors, allowing the controller to manage the lifting device and ventilation device based on predetermined threshold values, ensuring seamless container removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual alternation between lifting and ventilation modes is used, then the follower plate can be removed from the container, but the process requires operator expertise and is difficult to operate
Solution Approach 1:
The system performs the switch-over between lifting and ventilation modes automatically based on sensor feedback, eliminating the need for manual operator intervention. The controller monitors the characteristic variable and autonomously determines when to switch modes, making the system self-regulating and easier to operate.
Solution Approach 2:
A sensor continuously monitors a characteristic variable (such as force or position) and provides feedback to the controller. The controller uses this feedback to automatically switch between lifting and ventilation modes when predetermined threshold values are reached, enabling automated operation without requiring operator expertise.
2Extent of automation
If automated switch-over is implemented using sensors and controllers, then operator dependency is reduced, but the device complexity increases
Solution Approach 1:
The sensor monitors a characteristic variable and provides feedback to the controller, which automatically switches between lifting and ventilation modes based on predetermined threshold values. This feedback mechanism enables automated operation while keeping the control logic relatively simple.
Solution Approach 2:
The manual mechanical operation of switching between lifting and ventilation modes is replaced by an automated control system that uses sensor feedback and electronic control. This substitution reduces operator dependency while implementing automation through electronic rather than mechanical means.
3Force
If the follower plate is raised in lifting mode, then the container interior creates a vacuum that prevents further raising, but ventilation mode allows air intake
Solution Approach 1:
The system alternates between lifting mode and ventilation mode in periodic cycles. During lifting mode, the follower plate is raised creating a vacuum. When a threshold is reached, the system switches to ventilation mode to allow air intake, then returns to lifting mode. This periodic alternation prevents excessive vacuum formation while enabling continuous raising of the follower plate.
Solution Approach 2:
Before the vacuum becomes problematic and prevents further raising, the system proactively switches to ventilation mode to introduce air into the container. This preliminary anti-action counteracts the vacuum formation before it reaches a level that would stop the lifting process.
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
This automation simplifies the removal process, reducing operator dependency and ensuring consistent, efficient removal of the follower plate from the container, enhancing the overall efficiency of viscous material handling.
Implementation Method 1
at least one sensor (56), in particular a force measurement sensor, by means of which a characteristic variable that characterizes the position of the container (12) and/or of the follower plate (18) is ascertained
Implementation Method 2
the follower plate (18) is raised in a lifting mode by means of a lifting device (30)
Implementation Method 3
air is introduced into the container (12) in a ventilation mode by means of a ventilation device (46), by way of the ventilation opening (44), and the excess pressure that forms in the container presses it downward again
Implementation Method 4
a vacuum will occur in the container, which prevents the follower plate from being moved out. When the follower plate is raised, it raises the container with it as the result of the partial vacuum that occurs in the container as well as by means of the adhesion friction of its seals that lie against the inner surface of the container mantle
Data Source
AI summary
A method removes a follower plate of a device for transporting viscous material out of a barrel-like container. The device has the follower plate for closing the container, which is open at the top and has a container base and a container casing extending upwards from the base, the follower plate being movable toward and away from the base. A force measuring sensor measures a force exerted by a container onto a placement surface; the controller switches the ventilation mode to the lifting mode if the force exerted by the container onto the placement surface exceeds a first target force value; and the controller switches the lifting mode to the ventilation mode if the force exerted by the container onto the placement surface falls below a second target force value, and/or the at least one sensor measures the position of the container relative to a stationary point.