Hopper Control Actuator with Magnetic Switch
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing hopper control systems in the poultry industry face reliability issues due to exposure to extreme dust and moisture, mechanical failures, and premature wear of components, leading to inefficient feed distribution and animal stress.
Innovation Solution
A hopper control actuator using a magnetically actuated micro-switch within a sealed electrical enclosure, eliminating direct contact and utilizing a sliding member with complimentary corners to prevent rotation, ensuring reliable operation in harsh environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a flap design with micro switch is used inside the hopper, then the control system is simple, but the hinge becomes clogged with dust and debris causing reliability issues
Solution Approach 1:
The micro switch is extracted from the feed flow environment and mounted outside the hopper on a support structure. The actuator mechanism extends into the hopper to detect feed levels without exposing the switch itself to dust and debris, thereby maintaining reliability while preserving control system simplicity.
Solution Approach 2:
An actuator mechanism serves as an intermediary between the feed environment and the micro switch. The actuator extends into the hopper to sense feed presence and transmits this information to the protected micro switch, allowing the switch to operate reliably without direct exposure to harmful feed conditions.
2Measurement precision
If the micro switch is exposed to feed flow, then it can detect feed levels directly, but dust and debris cause the switch to malfunction
Solution Approach 1:
The actuator mechanism acts as an intermediary that extends into the feed flow to detect feed levels while keeping the micro switch protected outside the hopper. This allows accurate feed level detection through the actuator's position changes without exposing the switch to dust and debris that would cause malfunctions.
3Reliability
If the hopper runs empty due to switch failure, then energy is wasted running motors, but the switch is needed to detect feed levels
Solution Approach 1:
The micro switch is extracted from the feed environment and mounted outside the hopper where it is protected from dust and debris. This positioning ensures reliable operation that accurately detects when the hopper is empty, preventing unnecessary motor operation and energy waste while maintaining continuous monitoring capability.
4Reliability
If a suspended design with contacting flange is used, then the switch operates outside feed flow, but the flange rotation causes the micro switch to fall out of adjustment range
Solution Approach 1:
The mechanical contacting flange system is replaced with a magnetic actuator system. The actuator uses magnetic fields to actuate the micro switch without requiring physical contact or precise angular alignment, eliminating the problem of the switch falling out of adjustment range due to flange rotation while maintaining protection from feed flow.
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 solution provides a reliable and efficient hopper control system that withstands harsh conditions, reduces motor stress, and prolongs the lifespan of electric motors and micro-switches, ensuring consistent feed supply and minimizing animal distress.
Implementation Method 1
A hopper control actuator uses a magnetically actuated micro-switch within a sealed electrical enclosure, eliminating direct contact
Data Source
AI summary
A hopper control actuator is provided. The actuator has a frame having a first bracket at a top end for attaching to a hopper, a second bracket at a bottom end for attaching to an overhead support, and at least one strut between the top end and bottom end; a sliding member attached to the frame having of an outer tube, an inner tube and a spring, the inner tube being slidable within the outer tube and having a first magnet affixed on an exterior surface thereof, the spring being connected to the inner tube and the first bracket, the inner tube and the outer tube having complimentary corners to prevent rotation; and an electrical enclosure having a micro-switch mounted therein, the electrical enclosure being attached to the at least one strut and the micro-switch having an actuating lever with a second magnet affixed thereto such that a like pole faces a like pole of the first magnet along a length of a path of travel of the first magnet.