Granular Material Measuring Device with Segmented Gate Control
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Solution Overview
Problem
Existing measuring devices for granular substances lack the capability to measure at high speed and with high accuracy, particularly in supplying sand efficiently.
Innovation Solution
A measuring device with a hopper, a gate with a unique pass-through structure, and a control mechanism that adjusts the gate's position based on weight measurements to optimize supply rate and precision, using a driving mechanism and servo motor for accurate control, and a vibrator to ensure smooth flow even in packed conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the gate opening is fully opened to increase supply speed, then productivity improves, but measurement precision deteriorates due to difficulty in controlling the exact target weight
Solution Approach 1:
The gate opening is divided into multiple stages: first opening the first pass-through portion fully for high-speed supply, then sequentially opening the second pass-through portion for fine-tuned control. This segmentation allows the system to achieve both high productivity during the first stage and high measurement precision during the second stage, resolving the contradiction between supply speed and weight control accuracy.
2Measurement precision
If the gate closes completely to stop supply, then measurement precision improves by avoiding overflow, but productivity decreases due to longer cycle time
Solution Approach 1:
The control section predicts the optimal closing timing based on the supply rate and target weight before the actual closing occurs. This preliminary action allows the gate to close at the precise moment when the target weight is reached, preventing overflow while minimizing the cycle time. The servo motor executes the closing action quickly and accurately based on this pre-calculated timing.
3Device complexity
If a simple timer control is used to stop sand supply, then device complexity is reduced, but measurement precision deteriorates due to inability to adapt to actual supply rate variations
Solution Approach 1:
The control section continuously monitors the supply rate and uses this feedback to dynamically adjust the gate closing timing. By comparing the actual supply rate with the target weight, the system calculates the optimal moment to close the gate, ensuring high measurement precision. This feedback mechanism allows the system to adapt to variations in supply rate without requiring overly complex hardware.
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
Enables high-speed and accurate measurement of granular substances by controlling the supply rate and preventing overflow, ensuring the target weight is reached with precision and minimizing excess material.
Implementation Method 1
a measuring section that is provided at a lower side of the hopper, and that measures a weight of the granular substance that is supplied from the supply port
Data Source
AI summary
An opening portion that is formed so as to pass-through an opening/closing plate portion of a gate, can be disposed at a region overlapping a lower end opening of a hopper. The opening portion is structured by a first pass-through portion, and a second pass-through portion that is formed so as to be continuous with the first pass-through portion. A width, in a direction orthogonal to a lined-up direction in which the first pass-through portion and the second pass-through portion are lined up, is narrower than the first pass-through portion. Further, a driving mechanism moves the gate such that the opening/closing plate portion moves in the lined-up direction as seen in a plan view. Based on a preset target value of weight of sand, a control section controls the driving mechanism so as to decrease an amount of overlap of the opening portion of the gate and the lower end opening of the hopper in a stepwise manner in accordance with an increase in the weight of the sand measured by a scale.