Load Cell Array Estimation for Uninterrupted Weighing
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Solution Overview
Problem
Weighing systems often fail to detect failed load cells in real-time, leading to inaccurate weighing operations and resulting in economic losses and resource wastage due to the continued use of faulty systems until manual inspection.
Innovation Solution
A method where load cells are arranged in a local small neighborhood configuration, allowing for the estimation of failed load cell outputs using linear and non-linear coefficients determined from experimental data, enabling uninterrupted weighing by combining normal and estimated load cell outputs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the weighing system continues operation after load cell failure without timely detection, then productivity is maintained, but measurement precision deteriorates due to inaccurate weighing data
Solution Approach 1:
The patent implements a feedback mechanism where the weighing control module continuously monitors the output signals of all load cells, compares them with expected values based on local small neighbourhood relationships, and automatically detects failures. This real-time feedback enables timely identification of failed load cells, preventing continued use of inaccurate weighing data while maintaining system operation.
2Measurement precision
If the weighing system stops operation to replace failed load cells, then measurement precision is restored, but productivity decreases due to forced suspension
Solution Approach 1:
The patent introduces an intermediary estimation mechanism using the local small neighbourhood concept. When a load cell fails, the system uses the outputs of surrounding normal load cells to estimate the failed load cell's output through linear or non-linear relationships. This intermediary approach allows the system to compensate for failures and maintain accurate weighing operations without stopping, thus preserving productivity while ensuring measurement precision.
3Measurement precision
If manual inspection is used to detect load cell failures, then measurement precision can be restored, but loss of time increases due to delayed detection
Solution Approach 1:
The patent implements a self-service detection system where the weighing control module automatically monitors load cell outputs and identifies failures using the local small neighbourhood comparison method. The system performs self-diagnosis by comparing each load cell's output with the expected value derived from its neighbours, eliminating the need for manual inspection. This automated self-detection significantly reduces detection time and enables immediate response to failures.
4Device complexity
If all load cell outputs are simply synthesized without failure detection, then device complexity is minimized, but reliability deteriorates due to undetected failures
Solution Approach 1:
The patent applies preliminary action by pre-establishing the local small neighbourhood relationships and expected output relationships among load cells during system setup. These pre-defined relationships enable the weighing control module to quickly detect failures by comparing real-time outputs against expected values, without requiring complex real-time analysis. This preliminary preparation maintains relatively simple device complexity while significantly improving reliability through automated failure detection.
Data Source
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AI summary
The present invention discloses a weighing system and a weighing method having uninterrupted weighing functions. A plurality of load cells in the weighing system are arranged so that each load cell has a local small neighborhood, the local small neighborhood being a neighborhood defined by four neighboring points in front, back, left, and right of the load cell and four points on the diagonal directions in a matrix. A weighing control module polls the plurality of load cells to determine whether there is failed load cell(s), and performs the following calculation: W. = f (W1,W2,W3,W4,W5,W6,W7), where f is a non-linear mapping; W1 ···W8 represent the weighing outputs of load cells corresponding to the eight points in the local small neighborhood, respectively, so as to calculate the estimated weighing output of the failed load cell. Thus, wastes on time, resource, and humans are avoided that are caused by the situation that a load cell cannot be timely replaced when the load cell fails or during the weighing procedure.