Parallel Conveyor Assembly for Wide-Range Flow Switching
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Solution Overview
Problem
Conventional conveyor systems are inefficient when dealing with high ratios of maximum to minimum flow rates, as they operate at full power for maximum flow and become energy-inefficient at lower flow rates, leading to turbulence and cavitation issues.
Innovation Solution
A conveyor assembly with two parallel conveyor elements, each controlled by a flow controller, where a changeover device switches between them based on target flow value thresholds to optimize energy usage and prevent cavitation, ensuring stable operation by using a tracking value and ramp generator for smooth transitions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single conveyor element operates at full power to convey maximum flow rate, then the maximum flow rate requirement is met, but energy consumption increases and efficiency decreases at lower flow rates
Solution Approach 1:
The patent divides the conveyor system into multiple conveyor elements (at least two) that can operate independently or in combination. Each conveyor element is sized to handle a portion of the total flow rate, allowing the system to segment the flow handling task and activate only the necessary number of elements based on current demand, thereby reducing energy consumption when maximum flow is not required.
Solution Approach 2:
The patent implements dynamic control of conveyor elements based on real-time flow rate requirements. The system continuously monitors the actual flow rate and dynamically adjusts which conveyor elements are active and at what power levels, switching between different operational configurations to optimize energy efficiency while meeting flow demands.
2Productivity
If a valve is used to throttle flow rate, then flow rate control is achieved, but cavitation occurs in the valve gap leading to wear
Solution Approach 1:
Instead of using a single valve to throttle flow, the patent segments the flow control function across multiple conveyor elements. By activating different numbers and combinations of conveyor elements, the system achieves flow rate control without the need for excessive throttling, thereby avoiding cavitation and the associated wear that would occur in valve gaps.
Solution Approach 2:
The patent replaces the mechanical throttling mechanism (valve) with a more sophisticated control system that uses multiple conveyor elements with variable speed drives. This substitution eliminates the need for extreme valve opening/closing operations that cause cavitation, replacing them with smoother, more efficient flow control through coordinated operation of multiple elements.
3Productivity
If a single conveyor element operates below minimum flow rate, then flow rate adjustment is possible, but turbulence occurs and operation becomes inefficient
Solution Approach 1:
The patent segments the flow handling capacity across multiple conveyor elements, each designed to operate efficiently within an optimal flow range. When total flow requirements fall below the minimum efficient operating point of a single element, the system activates only the necessary portion of the total capacity by selectively operating one or more elements at reduced levels, maintaining laminar flow conditions and avoiding turbulence.
4Adaptability or versatility
If the ratio between maximum and minimum flow rates is high (e.g., 5:1 or more), then the conveyor element must be oversized for maximum flow, but it becomes energy-inefficient at lower flow rates
Solution Approach 1:
The patent addresses high flow rate ratios by segmenting the total conveyor capacity into multiple elements of appropriate sizes. This allows the system to handle maximum flow rates when all elements operate at full capacity while efficiently handling minimum flow rates by activating only the necessary subset of elements, thereby maintaining energy efficiency across the entire operating range without requiring any single element to be oversized.
Solution Approach 2:
The patent creates a multi-functional conveyor system where multiple conveyor elements can be selectively activated based on flow requirements. Each element serves multiple purposes: handling peak flows when combined with others, and handling low flows independently when needed. This universality allows the system to adapt to varying flow demands while maintaining optimal efficiency at each operating level.
Data Source
AI summary
A conveyor assembly for a medium, wherein the medium is conveyed from a source location to a destination via a conveyor line, where the conveyor line includes a conveyor section arranged between the source location and the destination and the conveyor section is equipped with two conveyor elements that are connected in parallel to each other and that are controlled by a respective flow controller, where the same flow target value and the same flow actual value are fed to both flow controllers, and the flow controllers ascertain a respective correcting variable for each conveyor element from said values, where a changeover device of the conveyor assembly prevents actuation of one conveyor element by one flow controller and releases the actuation of the other conveyor element by the other flow controller if the flow target value is above or below upper and lower changeover thresholds.