Optical Bulk Solids Metering for Stable Column Flow Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing bulk material flow measurement and metering apparatuses are energy inefficient, require complex variable speed drives, and lack indicators for proper functioning, making them difficult to operate and prone to errors such as plugging or running empty.
Innovation Solution
A volumetric flow measuring and metering apparatus with a conical obturating device and optical flow sensor that measures the speed of bulk material flowing through a vertically arranged flow passage with smooth, parallel sides, allowing for easy control of flow rate and volume measurement, and includes a controller to maintain a consolidated column-like flow and detect potential blockages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If rotating meters with flutes or cups are used to measure bulk material flow, then volumetric measurement is achieved, but energy consumption increases and device complexity increases due to variable speed drives
Solution Approach 1:
The patent replaces the mechanical rotating meter system with an optical measurement system. A laser transmitter and receiver measure the flow rate of bulk material without mechanical contact, eliminating the need for rotating components and variable speed drives while maintaining measurement precision.
Solution Approach 2:
The patent introduces an optical intermediary (laser beam) to measure bulk material flow. The laser transmitter and receiver detect flow characteristics through the material without mechanical interaction, serving as a non-contact mediator that eliminates energy-consuming mechanical components.
2Measurement precision
If rotating meters with flutes or cups are used to measure bulk material flow, then volumetric measurement is achieved, but device complexity increases due to variable speed drives
Solution Approach 1:
The patent replaces the mechanical rotating meter system with an optical measurement system. A laser transmitter and receiver measure the flow rate of bulk material without mechanical contact, eliminating the need for rotating components and variable speed drives while maintaining measurement precision.
3Ease of operation
If existing metering systems operate without monitoring, then simple operation is maintained, but reliability decreases due to undetected plugging or empty conditions
Solution Approach 1:
The patent incorporates feedback mechanisms where the laser transmitter and receiver continuously monitor bulk material flow characteristics. The system provides real-time feedback on flow rate and detects anomalies such as plugging or empty conditions, maintaining operational simplicity while improving reliability through automatic monitoring.
Solution Approach 2:
The measurement system performs self-monitoring of bulk material flow conditions. The optical sensors automatically detect flow characteristics and malfunctions without requiring external intervention, enabling the system to service itself by identifying problems like plugging or empty states.
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 apparatus is energy efficient, easy to clean, has a long service life, and provides accurate measurement and control of bulk material flow, ensuring consistent density and flow rate while minimizing the risk of plugging or empty conditions.
Implementation Method 1
an optical flow sensor that measures the speed of bulk material flowing through a vertically arranged flow passage
Implementation Method 2
flowable granular solids move in a mostly vertical direction down through a measuring chamber (flow passage) under the force of gravity
Data Source
AI summary
A volumetric flow measuring and metering apparatus for flowable solids has an upright flow passage through which a flow of bulk material can pass. A speed sensor measures a speed of the flow. An actuator controls an obturating device operative relative to a bottom end of the flow passage. A controller receiving speed data from the speed sensor operates the actuator at least in part based on information contained in the speed data in a manner causing the bulk material to flow in the flow passage at a location of the speed sensor in a consolidated column-like flow.