Particulate Flow Smoothing via Bin Level Control
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Solution Overview
Problem
Irregularly flowing streams of solid particulates lead to uneven finished products, particularly in smaller volumes, resulting in inconsistencies in coating applications, such as hormone distribution in animal feed, which affects product quality and producer profitability.
Innovation Solution
A system comprising a bin with a level sensor and controller, a movable valve, and a solids flow meter to convert irregular particulate flow into a continuously flowing stream, ensuring a constant output and allowing for precise coating and proportionate mixing of additional products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If bulk particulate material is transported via conveyor or hopper for further processing, then material handling is simplified, but irregular flow variations occur ranging from 20% to 50%
Solution Approach 1:
The system performs preliminary action by maintaining a controlled inventory of particulate material in a hopper and using a surge bin to pre-regulate flow before processing. The level sensor and controller proactively maintain set point levels, preventing irregular flow variations before they affect the processing operation.
Solution Approach 2:
The patent introduces an intermediary flow control system between the bulk material source and the processing equipment. The movable valve, level sensor, and controller act as mediators that decouple the irregular bulk flow from the processing operation, transforming it into a uniform stream suitable for precise coating or mixing operations.
2Productivity
If irregular flow is processed directly, then processing speed is maintained, but coating uniformity deteriorates with variations up to 50%
Solution Approach 1:
The system implements feedback control by continuously monitoring the particulate level in the hopper with a level sensor and adjusting the movable valve position based on the controller's calculations. This closed-loop feedback maintains consistent flow rates and set point levels, ensuring uniform coating application while sustaining productivity.
Solution Approach 2:
The patent applies dynamics by using a movable valve that can dynamically adjust its opening position in response to changing flow conditions and level variations. This dynamic adjustment capability allows the system to maintain uniform flow rates despite variations in bulk material supply, ensuring consistent coating quality throughout the processing operation.
3Reliability
If more feed is fed to animals to compensate for hormone under-ingestion, then hormone intake is sufficient, but producer profitability decreases
Solution Approach 1:
The patent replaces crude mechanical bulk handling with a precisely controlled flow system. The level sensor, controller, and movable valve create a metering system that accurately dosages particulate material, ensuring consistent hormone distribution in feed. This substitution of precise flow control for bulk handling eliminates the need to overfeed animals, maintaining profitability while ensuring adequate hormone intake.
Data Source
AI summary
A system for converting an irregular flow stream of solid particulates into a continuously flowing stream of solid particulates is disclosed. The system comprises a bin adapted to receive the irregular particulate flow stream. A level sensor is adapted to produce an output signal representative of the volume of particulates in the bin. The bin level controller has a set point corresponding to a desired level for the volume of particulates in the bin and is adapted to receive the output signal from the level sensor. The bin level controller produces a bin level control signal proportional to the deviation from the set point signal. A movable valve is positioned proximate the outlet adapted to modulate the particulate flow stream out of the bin and a valve controller is operatively associated with the valve. The valve controller is adapted to respond to bin level control signals from the bin level controller. The bin level controller is constructed and arranged to operate the valve such that the volume of particulates remains at the bin set point level to ensure a constant stream of particulates out of the bin through the outlet. Once the particulate flow stream is continuous and measured, it may be subjected to further operations such as proportional coating or mixing of additional constituents.