Material Column Infeed Pipe With Sensor-Based Level Detection
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Solution Overview
Problem
Existing devices for producing material columns in the ground face challenges in efficiently monitoring the filling level of bulk material in the infeed pipe, leading to inefficiencies and increased costs due to excess consumption, especially when encountering softer ground layers or cavities.
Innovation Solution
The implementation of a sensor device to detect the filling level down to the lower region of the infeed pipe, combined with a closed housing receiving bunker and a closable supply opening, allows for precise monitoring and controlled supply of bulk material, ensuring efficient production of material columns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a lock door is arranged between the upper receiving bunker and the infeed pipe to seal off the infeed pipe in a pressure-tight manner, then pressure can be built up inside the infeed pipe and maintained when the receiving bunker is open for loading bulk material, but the machine operator has no direct view of the filling level of the infeed pipe, making it difficult to estimate whether there is too much, too little or sufficient bulk material
Solution Approach 1:
The patent replaces the mechanical visual inspection method with a sensor-based detection system. A sensor device is arranged in the receiving bunker to detect the filling level of bulk material in the infeed pipe, converting the mechanical/visual information gathering into an automated sensing system that provides data without compromising pressure integrity
Solution Approach 2:
The sensor device acts as an intermediary between the bulk material in the infeed pipe and the control system. It transmits filling level information through the sealed system boundary, allowing indirect observation of the filling level without physically opening the sealed connection between the receiving bunker and infeed pipe
2Reliability
If a certain excess quantity of bulk material is introduced into the infeed pipe compared to the theoretically calculated material requirement to avoid insufficient design when encountering softer ground layers or cavities, then incomplete design of the material column is avoided, but unnecessary additional consumption occurs, leading to increased costs and effort
Solution Approach 1:
The sensor device provides real-time feedback on the actual filling level of bulk material in the infeed pipe during operation. This feedback mechanism allows the system to monitor and adjust bulk material supply dynamically, replacing the static excess provision approach with an adaptive control system that responds to actual ground conditions and filling requirements
Solution Approach 2:
The patent transforms the static, predetermined bulk material quantity approach into a dynamic system where the filling level is continuously monitored and adjusted based on actual operational needs. The sensor-enabled system allows real-time adaptation of material supply rates, replacing fixed excess provisioning with flexible, condition-based material delivery
3Productivity
If the infeed pipe is always emptied when the vibrating tamping column is created, then the material column is formed, but the lack of filling level monitoring results in inefficient material usage and increased consumption
Solution Approach 1:
The sensor device establishes a feedback loop that monitors the filling level in the infeed pipe and provides information to the control system. This enables the system to optimize bulk material supply timing and quantity, ensuring material is available when needed without continuous excess provisioning, thereby improving production efficiency while reducing waste
Solution Approach 2:
The sensor device enables preliminary detection of filling levels, allowing the control system to prepare and adjust bulk material supply in advance of actual consumption needs. This preliminary information gathering allows optimized timing of material replenishment, avoiding both shortages that halt production and excesses that waste material
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 solution enables accurate detection of filling levels, allowing for efficient and economical production of material columns by ensuring the right amount of bulk material is used, reducing unnecessary consumption and improving quality control.
Implementation Method 1
a sensor device is arranged, which is designed to detect a filling level of bulk material down to a lower region of the infeed pipe
Implementation Method 2
a compressed air supply device for introducing compressed air into the inside of the infeed pipe
Implementation Method 3
a vibrating drive, which is designed to cause the infeed pipe to vibrate
Data Source
AI summary
The invention relates to a device for producing a material column, in particular a vibrating tamping column, from a bulk material in the ground, having an infeed pipe, which is designed to be driven into the ground and has at least one material outlet opening at a lower end, a vibrating drive, which is designed to cause the infeed pipe to vibrate and is arranged, in particular, on a lower region of the infeed pipe, a receiving bunker, which is designed to receive a quantity of bulk material and is arranged on an upper region of the infeed pipe, and a compressed air supply device for introducing compressed air into the inside of the infeed pipe. According to the invention, it is provided that a sensor device is arranged, which is designed to detect a filling level of bulk material down to a lower region of the infeed pipe, that the receiving bunker is designed with a closed housing with a closable supply opening for supplying bulk material into the receiving bunker, wherein the supply opening can be closed in an airtight manner by means of a closing device, and that a passage between the receiving bunker and the infeed pipe being arranged below, is open when the bulk material is inserted into the ground, wherein the filling level of bulk material in the infeed pipe can be detected by the sensor device. The invention also relates to a method for filling a device for producing a material column.