Shear-Web Load Cell for Silo Weight Monitoring
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Solution Overview
Problem
Existing silo monitoring systems are cumbersome, requiring large footprints, complex installations, and heavy machinery for lifting and replacing load cells, which leads to inefficiencies and increased costs, especially when dealing with small concrete blocks and heavy silo loads.
Innovation Solution
A system utilizing a custom-designed shear-web type load cell with integrated strain gauges and a lever mechanism for lifting, allowing secure installation without cranes and specialized tools, with a compact design that distributes load across two support locations for heavier lifting capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a mechanical connector vertically mounted to a S-type load cell is used, then the load cell can measure the weight of the silo, but the assembly requires increased ground clearing and has a very large footprint
Solution Approach 1:
The load cell assembly is divided into separate functional components: the load cell itself, the connector, and the lifting mechanism. This segmentation allows each component to be optimized independently and assembled in a compact configuration that reduces the overall footprint while maintaining measurement precision.
Solution Approach 2:
The patent transitions from a vertical mounting approach (which requires ground clearing) to a horizontal/compact arrangement where the load cell, connector, and lifting mechanism are arranged in a space-efficient configuration. This dimensional reorganization reduces the footprint without compromising the weight measurement capability.
2Measurement precision
If a mechanical connector vertically mounted to a S-type load cell is used, then the load cell can measure the weight of the silo, but the assembly requires a beefy and large A-Frame structure
Solution Approach 1:
The patent extracts the lifting function from the structural support system. Instead of requiring a large A-Frame to provide both support and lifting capability, the design separates the lifting function into an independent mechanism that attaches to the load cell assembly, thereby simplifying the overall structure.
Solution Approach 2:
The load cell assembly is designed as a universal module that can be attached to various silo configurations without requiring custom structural support. The standardized connector and lifting mechanism can be applied to different silo types, reducing the need for specialized A-Frame structures.
3Measurement precision
If a system requiring a connector arranged to be connectable to one of the bin legs is used, then the load cell can be attached to the silo, but the complexity and costs of installation increase
Solution Approach 1:
The connector is pre-assembled with the load cell as an integrated unit before installation at the silo. This preliminary assembly eliminates the need for complex on-site connection procedures and reduces installation complexity, as the complete module can be attached as a single unit to the silo leg.
4Reliability
If multiple pieces are required to properly attach the silo leg to the load cell, then the connection can be secure, but the installation time and complexity increase
Solution Approach 1:
Multiple connection components are merged into a single integrated connector assembly that attaches the silo leg to the load cell as one unit. This consolidation maintains the security of the connection while significantly reducing installation time, as only one attachment operation is required instead of multiple separate steps.
5Ease of repair
If heavy lifting equipment is required for replacing load cells, then the load cell can be replaced, but the intervention becomes complex and time-consuming
Solution Approach 1:
The lifting mechanism incorporates a counterbalancing design that offsets the weight of the load cell and connector assembly. This allows the lifting mechanism to operate with minimal force, eliminating the need for heavy lifting equipment and simplifying the replacement process.
Solution Approach 2:
The lifting mechanism is designed to be self-contained and can be operated manually or with minimal assistance. The integrated lifting mechanism allows the load cell assembly to be lifted and replaced without requiring external heavy equipment, making the repair process more accessible and time-efficient.
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
Enables secure, efficient monitoring and lifting of silos with reduced installation complexity and machinery needs, allowing for uninterrupted feeding and minimizing manual effort, while maintaining stability in windy conditions.
Implementation Method 1
at least one measuring means, such as a strain gauge, attached to the load cell for measuring the deformation of the load cell
Data Source
AI summary
A method and apparatus to monitor the weight of a silo or tank is disclosed. The system is adapted to be attached to a leg of the silo and comprises a load cell, a support member anchored to the ground and a lifting device attached to the load cell and to the support member. The load cell comprises two extremities that are attached to the silo leg and comprises an aperture there between. The aperture is preferably threaded to receive the lifting device, such as a bolt. The bolt is rotated using a tool as to induce a movement of the load cell along the axis of the bolt thereby lifting the load cell and the attached silo leg. Strain gauges are attached to the load cell to measure the variation in an electric or optical signal that is translated in human readable data using a monitoring device.