Weighing Scale With Integrated Signal Processing For Strand Items
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing scales for weighing strand-shaped items face challenges in achieving high accuracy while minimizing installation space and cost, particularly when dealing with items of different lengths, as they often require additional sensors and complex signal processing, which can lead to delays and inaccuracies due to drift and product buildup.
Innovation Solution
A scale design featuring a short weight sensor roller with an integrated evaluation device that includes an integrator and differentiator for real-time signal processing, eliminating the need for intermediate storage and additional sensors, and using correction factors to maintain accuracy over time, along with a microprocessor for communication and control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a long weight sensor is used to weigh strand-shaped items, then the measurement accuracy is improved, but the installation space requirement increases
Solution Approach 1:
The weighing process is segmented into multiple measurement points along the strand. Instead of using a single long sensor, the system uses a short sensor that measures weight at one location while the strand moves through, capturing weight data at different positions sequentially to achieve complete weighing accuracy.
Solution Approach 2:
The solution transitions from a spatial extension (long sensor) to a temporal dimension by utilizing the movement of the strand through the short sensor over time. The weighing process is extended in time rather than in space, allowing complete measurement without increasing sensor length.
2Measurement precision
If additional sensors are used to determine start and stop times, then the measurement accuracy is improved, but the device complexity and cost increase
Solution Approach 1:
The functions of weight measurement and timing detection are merged into a single weight sensor system. The start and stop times are determined by analyzing the weight signal itself rather than using separate sensors, reducing component count while maintaining measurement accuracy.
Solution Approach 2:
The weight sensor serves multiple functions: it measures the weight of the strand and simultaneously detects the start and stop times of the weighing process by monitoring when the weight signal begins and ends. This multi-functionality eliminates the need for additional dedicated timing sensors.
3Measurement precision
If a long weight sensor is used, then the measurement accuracy is improved, but the cost of the scale increases
Solution Approach 1:
The weighing measurement is segmented into multiple readings taken as the strand passes through the short sensor, rather than requiring a single long sensor. This approach achieves complete weighing accuracy using a shorter, less expensive sensor.
Solution Approach 2:
The solution replaces an expensive long sensor with a more affordable short sensor, accepting that the measurement process will take longer but reducing the cost of the critical measurement component.
4Measurement precision
If signal processing is delayed for integration, then the measurement accuracy is improved, but the processing time increases
Solution Approach 1:
The weight signal is integrated in real-time as the strand passes through the sensor, rather than delaying processing. The integration accumulates weight data continuously during the measurement period, eliminating post-processing delays while maintaining accuracy.
Solution Approach 2:
The signal integration process operates continuously throughout the measurement period rather than in discrete batches. This continuous integration maintains measurement accuracy while minimizing processing time by eliminating idle periods between measurement and calculation.
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, real-time weighing of items of varying lengths with reduced installation space and cost, maintaining high accuracy by correcting for drift and eliminating the need for additional sensors, while allowing for efficient processing of measurement signals in a compact and cost-effective manner.
Implementation Method 1
a weight sensor (4) having a roller (41) which is connected to a load cell (42)
Data Source
Figure 1
Figure 2~3
AI summary
The machine (1) has an inlet conveyor belt (2) and an unloading conveyor belt (3) for transport of weighing goods. A weight accommodator (4) is arranged between the inlet conveyor belt and unloading conveyor belt. An evaluation device (5) has an integrator (51) for absorbing a signal of the accommodator over time to determine total weight of the goods. The evaluation device has a differentiator (52) for differentiating the signal over time, and automatically determines starting time and stopping time of measurement based on the differentiated signal.