Dynamic Vacuum Control for Milking Teat Cup Attachment
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Solution Overview
Problem
The existing milking systems face challenges with teat cup detachment during the milking process due to low vacuum levels, especially during high milk flow periods, which can lead to rapid disconnection of teat cups from the animal's teats.
Innovation Solution
A control unit in the milking system monitors air flow values and adjusts the vacuum level to maintain a higher suction force by applying a higher vacuum level when increased air flow or rapid air flow increase is detected, preventing teat cup detachment by reducing air leakage and maintaining a secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a reduced vacuum level is used during the milking process, then the risk of teat cup detachment is reduced for most cows, but the suction force becomes insufficient for high-producing animals during high milk flow periods
Solution Approach 1:
The vacuum level is made dynamic rather than static. The system continuously monitors air flow and automatically adjusts the vacuum level in real-time based on actual conditions. When air flow exceeds the threshold indicating potential detachment, the vacuum level increases to restore sufficient suction force, then returns to the reduced level when conditions normalize.
Solution Approach 2:
The system implements a feedback control mechanism where the air flow measurement serves as the feedback signal. The control unit compares the measured air flow against a predetermined threshold and adjusts the vacuum level accordingly, creating a closed-loop control system that maintains optimal teat cup attachment.
2Force
If a high vacuum level is applied continuously to prevent teat cup detachment, then the suction force is sufficient for all animals, but the risk of teat cup detachment during high milk flow periods increases due to air leakage
Solution Approach 1:
Instead of applying excessive vacuum continuously, the system applies a reduced vacuum level as the baseline (partial action) and only increases to high vacuum level when absolutely necessary to prevent detachment. This minimizes the time during which high vacuum is applied, reducing overall air leakage while maintaining sufficient suction force when needed.
3Force
If the vacuum level is increased to prevent teat cup detachment, then the suction force increases, but air leakage into the teat cup increases further decreasing the vacuum
Solution Approach 1:
The system takes preliminary action by detecting the tendency toward detachment through air flow monitoring before actual detachment occurs. By increasing the vacuum level at this early stage, the system prevents the development of air leakage paths that would otherwise form as the teat cup begins to separate, thereby avoiding the energy loss associated with maintaining vacuum against significant air leakage.
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 effectively prevents teat cup detachment by increasing the suction force between the teat cup and the teat, ensuring a secure connection and reducing the risk of teat cup loss during high milk flow periods, allowing for continuous and efficient milking.
Implementation Method 1
a vacuum source able to apply at least two different vacuum levels to the teat cup
Implementation Method 2
The vacuum level in the teat cups drops when the milk flow is high. Consequently, there is an increased risk for undesired detachment of teat cups during periods of the milking process when the milk flow is high.
Implementation Method 3
measuring device configured to measure the air flow in the milk line during the milking process
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a milking system and a method for preventing detachment of a teat cup from a teat of an animal during a milking process. The milking system comprises a milk line (lb, lc, 2) connected to the teat cup (1 a), a vacuum system able to apply at least two different vacuum levels to the teat cup (la) and a measuring device (4) configured to measure the air flow in the milk line (1 b, 1 c, 2) during the milking process. The milking system comprises a control unit (5) configured to receive information about measured air flow values and to determine if the teat cup (la) is about to be detached from the teat by comparing the measured air flow values (qa) with an acceptable value (qa1, Δqa1/Δt), if the measured air flow values are not acceptable, to control the vacuum system such that it applies a higher vacuum level to the teat cup (la) than the present vacuum level.