Powder Feeder Control Parameter Calculation for Granule Accuracy
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Solution Overview
Problem
Existing powder and granule feeding apparatuses require empirical skill for initial setup and adjustment of control parameters, leading to unstable and inaccurate feeding, resulting in raw material loss.
Innovation Solution
A method involving a filling, consolidation, and parameter calculation process to stabilize the powder state within the feeder, using speed control and parameter calculation units to determine accurate control parameters, including gain constants and time constants from discharge waveforms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If control parameters are adjusted in an unstable state (with gaps between powders and screw), then adjustment can be performed quickly, but the accuracy of obtained parameters will be low
Solution Approach 1:
The patent applies preliminary action by performing a consolidation process before parameter adjustment. The controller conducts a first conveyance at a first rotational speed to consolidate the powders, eliminating gaps between the powders and the screw. Only after this consolidation is complete does the controller proceed with parameter adjustment at a second, higher rotational speed. This ensures parameters are adjusted in a stable state, guaranteeing high accuracy without sacrificing time.
2Ease of operation
If empirical skill is used to adjust control parameters, then adjustment can be performed without complex procedures, but the accuracy of fixed amount feeding will be low
Solution Approach 1:
The patent implements self-service by enabling the system to automatically calculate and determine optimal control parameters through the consolidation process and waveform analysis. The controller autonomously performs the first conveyance at a predetermined rotational speed, analyzes the discharge amount waveform to extract time constant and dead time, and computes the optimal rotational speed for accurate feeding. This eliminates the need for operator empirical skill while ensuring high precision in fixed amount feeding.
3Speed
If powders are conveyed at high speed initially, then stable feeding state can be achieved faster, but gaps between powders and screw cannot be eliminated
Solution Approach 1:
The patent applies periodic action by using a two-stage conveyance process. First, the screw conveys powders at a lower first rotational speed to eliminate gaps and achieve uniform distribution. Then, after consolidation is complete, the screw switches to a second, higher rotational speed for actual feeding operation. This periodic variation in speed ensures both proper powder consolidation and efficient feeding performance.
Data Source
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AI summary
Providing a method for calculating a control parameter for a powder and/or granule feeding apparatus and the powder and/or granule feeding apparatus, which can improve feeding accuracy in fixed amount feeding of powders. The method is for calculating a control parameter used to control a discharge amount of powders G in a powder and/or granule feeding apparatus 100 including a hopper 11 into which powders G are charged, and a feeder 12 discharging the powders G outside the apparatus. The method comprises a step S12 of filling the powders G into the feeder 12 without creating any non-filled area by conveying the powders G at a predetermined speed within the feeder 12, the powders G are first charged at a beginning of operation; a step S13 of bringing the powders G into a consolidation state within the feeder 12 by conveying the filled powders G through the feeder 12 at a speed faster than the predetermined speed; and a step S16 of calculating the control parameter using the discharge amount of the powders G in the consolidation state.