Load Cell-Synchronized Bulk Metering Into Mixed Storage Vessels
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Solution Overview
Problem
The sequential metering and mixing of different bulk dry flowable materials for wellbore operations is time-consuming and costly, with existing systems requiring multiple transfers and manual intervention, leading to inefficiencies and potential human errors.
Innovation Solution
A controller-based dry flowable material dispensing system that uses static weight-based readings to synchronize the metering of different bulk materials into a mixed storage vessel over a comparable time period, ensuring homogeneous blending without layering, reducing the need for additional blending time and equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If sequential metering and mixing of different bulk dry flowable materials is used, then manufacturing precision is maintained, but productivity is reduced due to time-consuming processes
Solution Approach 1:
The system performs preliminary synchronization of metering operations for multiple bulk materials, coordinating their discharge rates before they enter the mixed storage vessel. This preliminary coordination ensures homogeneous blending occurs during the transfer process itself, eliminating the need for subsequent blending operations and significantly reducing total processing time.
2Ease of operation
If multiple transfers and manual intervention are used in existing systems, then ease of operation is maintained through simple equipment, but productivity is reduced due to inefficiencies and human errors
Solution Approach 1:
The controller receives real-time weight-based feedback from load cells monitoring each bulk storage container and dynamically adjusts the metering rate of each material accordingly. This closed-loop feedback system automatically coordinates the discharge of multiple materials to arrive simultaneously at the mixed storage vessel, eliminating manual intervention while ensuring precise blending ratios and homogeneous mixing.
3Ease of operation
If bulk materials are metered at different rates into a mixed storage vessel, then ease of operation is improved through independent control, but manufacturing precision deteriorates due to layering instead of homogeneous blending
Solution Approach 1:
The controller pre-calculates and synchronizes the metering rates of all bulk materials based on their respective quantities and desired final blend ratios. By coordinating the discharge timing and rates before materials enter the mixed storage vessel, the system ensures homogeneous blending occurs during transfer, eliminating layering while maintaining independent control capabilities for each material source.
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 system significantly reduces the metering time to 10 minutes or less, eliminates the need for additional blending, and minimizes human error, while ensuring accurate and continuous dispensing of bulk dry flowable materials.
Implementation Method 1
A controller-based dry flowable material dispensing system that uses static weight-based readings to synchronize the metering of different bulk materials
Data Source
AI summary
The system, in one aspect, includes a first bulk storage container for holding a first bulk dry flowable material having a first dispensing assembly coupled with a first outlet, and a second bulk storage container for holding a second bulk dry flowable material having a second dispensing assembly coupled with the second outlet. The system, in one aspect, may further include a mixed storage vessel, as well as a controller in communication with the first dispensing assembly and the second dispensing assembly, the controller programmed to cause the first dispensing assembly to discharge the first amount of the first dry flowable material to the mixed storage vessel and cause the second dispensing assembly to discharge the second amount of the second dry flowable material to the mixed storage vessel over a comparable time period based upon weight based readings the controller receives from first and second load cells.