Optical Feed Level Sensor for Poultry Control Feeder
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Solution Overview
Problem
Existing poultry feed systems face challenges in accurately detecting the feed level in control pans, leading to inefficient filling of feeders along the feed line, as mechanical switches and other methods are limited in precision and reliability.
Innovation Solution
A control feeder system equipped with a feed level sensor using light emitters and receivers positioned within the drop tube, which emits a 'start' signal when the feed level falls below a predetermined 'empty' level and a 'stop' signal when it reaches a 'full' level, allowing for precise control of feed delivery through the use of a circuit board and light guide to direct light along the drop tube.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If mechanical switches or proximity switches are used to detect feed level, then the device structure is simple, but the measurement precision and reliability are insufficient
Solution Approach 1:
The patent replaces mechanical switches and proximity switches with an optical sensing system consisting of light emitters and light receivers positioned within the drop tube. This substitution eliminates mechanical contact and improves measurement precision for detecting feed levels while maintaining relatively simple device structure through the use of standard optical components.
Solution Approach 2:
The patent introduces light as an intermediary medium to detect feed levels. Light emitters transmit light through the drop tube, and light receivers detect the light transmission status to determine feed presence and level. This intermediary approach enables precise non-contact measurement without requiring complex mechanical sensing structures.
2Reliability
If light emitters and receivers are positioned within the drop tube to detect feed level, then the measurement precision is improved, but the device complexity increases
Solution Approach 1:
The patent replaces unreliable mechanical sensing mechanisms with an optical detection system that uses light emitters and receivers positioned within the drop tube. This substitution significantly improves detection reliability by eliminating mechanical wear and contact issues, while the modular optical component design keeps the overall system complexity manageable.
Solution Approach 2:
The optical sensing system is designed to be self-regulating and maintenance-free. The light emitters and receivers automatically detect feed levels without requiring mechanical adjustment or calibration, improving reliability while minimizing the complexity of control mechanisms needed to operate the system.
3Measurement precision
If multiple light emitters and receivers are used to define multiple rows for detecting different feed levels, then the measurement precision is improved, but the device complexity and cost increase
Solution Approach 1:
The patent segments the optical sensing system into multiple rows of light emitters and receivers, with each row positioned at different heights within the drop tube to detect specific feed levels (empty level, full level, intermediate levels). This segmentation enables precise multi-level detection while using standardized optical components that can be replicated and assembled in a modular fashion, balancing precision requirements with component quantity.
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
Ensures accurate and efficient filling of feeders by activating and deactivating the feed delivery system based on precise feed level detection, reducing waste and ensuring consistent feeding in poultry houses.
Implementation Method 1
the at least one light emitter is positioned and adapted to transmit light through a length of the drop tube
Implementation Method 2
a light guide to direct light from the emitter into the drop tube, such that the light from the emitter is transmitted along a length of the drop tube
Data Source
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AI summary
A feed level sensor for a poultry feeding system is positioned within the drop tube of a control feeder of the feeding system. The sensor comprise a first light emitter/light detector pair to detect when the level of feed in the drop tube falls below a predetermined "empty" level and a second light emitter/light detector pair to detect when feed in the drop tube is at a predetermined "full" level in the drop tube. The sensor emits a "start" signal to activate a drive to deliver feed to the feeders along a feed line when it is detected that feed in the control feeder drop tube falls below the "empty" level and emits a "stop" signal to deactivate the drive when it detects that feed within the drop tube is at the "full" level.1.