Pulverizer Spring Assembly Load Cell Feedback
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Solution Overview
Problem
Current solid fuel pulverizers lack feedback mechanisms to accurately adjust and monitor the force applied during grinding, leading to potential operational issues and inefficiencies in achieving desired particle sizes.
Innovation Solution
A spring assembly with a load cell is integrated into the pulverizer to measure and provide feedback on the forces exerted by the springs, allowing for real-time monitoring and adjustment of the grinding force, comprising a spring housing, preload stud, stop plate, spring seat, and load cell to generate an electronic signal indicating the force applied.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual adjustment of spring force is used, then the device complexity is reduced, but the measurement precision and control accuracy of grinding force deteriorate
Solution Approach 1:
The patent implements a feedback mechanism by installing a load cell within the spring assembly to continuously measure the force applied by the spring. This measured force is then fed back to the control system, which automatically adjusts the spring preload to maintain the desired grinding force. This resolves the contradiction by providing accurate force measurement and control without requiring complex manual adjustment mechanisms.
Solution Approach 2:
The patent replaces the manual mechanical adjustment system with an automated electro-mechanical system. The load cell converts mechanical force into an electrical signal, which is then processed by a control system that automatically adjusts the spring assembly. This substitution eliminates the need for complex manual adjustment mechanisms while providing precise force measurement and control.
2Device complexity
If no feedback mechanism is installed, then the device complexity is reduced, but the reliability and operational safety deteriorate
Solution Approach 1:
The load cell provides continuous feedback on the spring force, allowing the control system to detect and correct deviations from the desired force level. This feedback mechanism enhances operational reliability by ensuring consistent grinding performance and enabling early detection of potential issues such as spring failure or abnormal wear conditions.
Solution Approach 2:
The system performs self-monitoring and self-adjustment through the load cell and control system. The automatic adjustment capability allows the pulverizer to maintain optimal performance without constant manual intervention, thereby improving reliability while keeping the overall system complexity manageable through automated self-service functions.
3Productivity
If real-time force monitoring is implemented, then the productivity and operational efficiency are improved, but the device complexity increases
Solution Approach 1:
The load cell integrated into the spring assembly provides real-time force monitoring, enabling the control system to make immediate adjustments to maintain optimal grinding conditions. This real-time feedback loop improves productivity by ensuring consistent particle size distribution and preventing operational inefficiencies, while the integration approach keeps the added complexity minimal.
Solution Approach 2:
The patent merges the force measurement function directly into the existing spring assembly structure by positioning the load cell within the spring housing. This integration combines multiple functions (spring loading and force measurement) into a single compact unit, thereby improving operational efficiency through real-time monitoring while minimizing the increase in overall device complexity.
4Ease of operation
If manual force adjustment is used, then the ease of operation is maintained, but the manufacturing precision and particle size control deteriorate
Solution Approach 1:
The load cell provides continuous feedback on the actual grinding force, allowing the control system to automatically adjust the spring preload to maintain the desired force level. This automated feedback mechanism ensures consistent particle size distribution by eliminating human error and variability in manual adjustment, thereby improving manufacturing precision while maintaining ease of operation through automatic control.
Solution Approach 2:
The patent replaces manual mechanical adjustment with an automated electro-mechanical control system. The load cell converts force into an electrical signal that is processed by the control system, which automatically adjusts the spring assembly. This substitution improves particle size consistency by eliminating the variability inherent in manual adjustment, while the automated system maintains ease of operation through simple setpoint specification.
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 enables precise control of the grinding force, improving the accuracy of particle size distribution, extending gearbox component life, and enhancing operational safety by allowing for real-time detection and correction of mechanical issues, thus facilitating efficient pulverization and emissions control.
Implementation Method 1
A load cell is positioned in the interior area of the spring housing for measuring forces exerted by the spring due to spring preload as well as movement of the spring seat relative to the spring housing
Data Source
AI summary
A pulverizer 60 includes a spring assembly 10 that urges a grinding roller 72 of a journal assembly 68 onto a grinding surface 66 of a grinding table 64. The force applied is monitored by a load cell 32 located within spring assembly 10 that creates an electronic signal. A controller 83 receives the electronic signal and stores and/or displays it and alternatively acts to adjust the applied force to a desired value. Alternatively, adjustable forces or mechanical dampening may be applied to journal assembly 68 by controller 83. Alternatively, additional sensors may measure displacement of the journal assembly and rotation of the grinding table for other calculations.