Hopper Gate Drive Control for Lower-Power Combination Weighing
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Solution Overview
Problem
Existing combination weighing apparatuses waste power due to fixed drive current control for hopper gates, despite varying torque needs based on open/closed positions, leading to inefficient power consumption.
Innovation Solution
A control unit dynamically adjusts power to the drive unit based on the opening and closing speed of the hopper gate, dividing the operation into intervals and setting specific power levels for each interval to match the gate's operational requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fixed drive current is supplied to the hopper gate to ensure stable operation, then reliable gate opening and closing is achieved, but power consumption increases due to wasteful continuous maximum power supply
Solution Approach 1:
The patent applies dynamics by transitioning from fixed drive current to variable drive current that changes according to the gate's opening/closing position. The control unit dynamically adjusts the drive current based on the detected gate position, supplying higher current when torque is needed (during movement) and lower current when the gate is stationary, thereby resolving the contradiction between reliable operation and power consumption.
Solution Approach 2:
The patent changes the parameter of drive current from a fixed value to a variable value that depends on the gate position. By detecting the gate position and corresponding the drive current value to this position, the system optimizes power consumption while maintaining reliable gate operation throughout the opening and closing cycle.
2Reliability
If maximum drive current is continuously supplied to the hopper gate, then the gate can be reliably opened and closed under all conditions, but power consumption becomes inefficient due to wasteful power supply during low-torque phases
Solution Approach 1:
The patent changes the drive current parameter from a constant maximum value to a variable value that corresponds to the gate position. The control unit stores multiple drive current values and selects the appropriate value based on the detected gate position, ensuring reliable operation while minimizing energy waste during phases when maximum torque is not required.
Solution Approach 2:
The system dynamically adjusts the drive current based on real-time gate position feedback. During startup and movement phases when torque is needed, higher current is supplied; during stationary phases, lower current is supplied. This dynamic adaptation resolves the contradiction between operational reliability and energy efficiency.
3Use of energy by moving object
If the drive current is adjusted according to gate position to reduce power consumption, then energy efficiency improves, but the control system complexity increases
Solution Approach 1:
The patent implements feedback by detecting the gate position and using this information to control the drive current. The control unit continuously monitors the gate position and adjusts the drive current accordingly, creating a closed-loop control system that optimizes power consumption while maintaining simple and reliable implementation.
Solution Approach 2:
The patent segments the gate operation into discrete position states, with each position corresponding to a specific drive current value. By dividing the continuous motion into discrete segments and assigning appropriate current values to each segment, the system achieves energy efficiency without requiring complex continuous control algorithms.
Data Source
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Figure 3A
AI summary
[Problem] To provide a combination weighing apparatus that reduces power consumption during opening and closing operations of a hopper gate. [Solution] In a combination weighing apparatus 1, a control unit 70 controls a stepping motor 60 via a control signal that is input to the stepping motor 60. The control signal that is input to the stepping motor 60 is a voltage value corresponding to a desired current value. The control unit changes the control signal to the stepping motor 60 in conjunction with a change in the settings of the opening and closing speed of the gate 20. As a result, it becomes possible to supply power needed for the operation of the gate 20, and power can be saved.