Rotating Produce Filling Head with Sensor Feedback
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Solution Overview
Problem
Existing bin-filling systems for agricultural produce suffer from irregular distribution and energy wastage due to continuous operation without adjusting to varying produce flow rates, leading to damage and inefficient use of bins.
Innovation Solution
A rotating filling head with sensors and adjustable rotation speed, which releases produce only in areas with low product height, ensuring uniform distribution and matching the filling head's operation with the produce flow rate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the filling head operates continuously without adjustment, then productivity is maintained, but energy is wasted and produce distribution becomes irregular
Solution Approach 1:
The filling head rotation speed is made dynamically adjustable to match the variable flow rate of produce from the grading system. The drive means can vary the rotation speed between 0.5-2 revolutions per second based on actual produce availability, preventing energy waste when produce flow is low while maintaining productivity when flow is high.
Solution Approach 2:
A sensor system detects the presence and height of produce in the bin, providing feedback to the control means. This feedback loop allows the system to automatically adjust the filling head operation—releasing produce only when the bin is not full and adjusting rotation speed based on produce flow rate, thereby optimizing both energy efficiency and productivity.
2Productivity
If the filling head operates continuously without adjustment, then productivity is maintained, but produce distribution uniformity deteriorates
Solution Approach 1:
The system applies local quality by releasing produce at specific locations within the bin based on sensor-detected height variations. The filling head rotates to position release points over different bin areas, ensuring produce is distributed uniformly across the entire bin surface rather than concentrating in one location.
Solution Approach 2:
The filling head rotation speed is dynamically adjusted to match produce flow rate, and the release mechanism operates dynamically based on real-time bin fill level detection. This dynamic operation ensures uniform distribution while maintaining continuous productivity.
3Productivity
If the filling head operates at high speed continuously, then productivity is improved, but produce damage increases due to excessive rubbing
Solution Approach 1:
The filling head rotation is converted from continuous operation to periodic operation. The head rotates and releases produce in periodic cycles synchronized with the grading system output and bin fill level. This periodic action reduces continuous rubbing of produce against the filling head, minimizing damage while maintaining productivity through optimized timing.
Solution Approach 2:
Sensor feedback on bin fill level and produce flow rate enables the system to adjust filling intensity and timing. When the bin approaches capacity or produce flow decreases, the system automatically reduces filling activity, preventing excessive rubbing and produce damage while optimizing productivity during high-flow periods.
4Device complexity
If the filling head operates without sensing bin fill level, then device complexity is reduced, but productivity decreases due to premature bin replacement
Solution Approach 1:
A sensor system provides feedback on bin fill level, enabling the control means to determine when the bin is actually full based on measured produce height. This feedback mechanism optimizes bin utilization by continuing to fill bins until truly full, reducing the number of bin replacements needed and improving productivity without excessive complexity.
Solution Approach 2:
The sensor system and control means create a self-regulating filling process that automatically monitors bin fill level and adjusts operation accordingly. The system serves itself by detecting when to stop filling a bin and when to replace it, eliminating the need for manual monitoring while maximizing bin utilization efficiency.
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
This solution achieves a uniform distribution of produce, reducing waste and energy consumption by adjusting the filling process based on real-time produce availability and distribution within the bin.
Implementation Method 1
a sensor, arranged in a position underlying said disk, and suitable to detect the presence of said products at a predefined vertical distance from the lower plate (4)
Implementation Method 2
a first continuous conveyor (11)...to engage said vegetable products in its upper portion and to carry them downward in a continuous vertical motion down to its lower portion, and to release them by gravity
Data Source
AI summary
A produce filling apparatus includes a bin filling head and a disk arranged under the head. The disk is made up of two plates, each having one or more openings. Plural sensors beneath the disk detect the presence of produce at a predefined vertical distance from the lower plate. A control unit detects the instantaneous position of both overlying rotating plates and determines the speed of rotation of each of the rotating plates in a manner that depends on a pre-coded external signal generated by the sensors and by the instantaneous positions of the rotating plates. The control unit processes the information received and controls the respective angular speed of the plates so that the respective openings are vertically aligned, so as to distribute the produce to those bins in which an absence of underlying produce is sensed.