Torque Sensing Automatic Transmission for Feed Mixers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Agricultural feed mixers face inefficiencies in power transmission and drive system protection due to manual gear shifting and reliance on weight-based torque calculations, which are unreliable, especially when mixing ingredients with varying densities, leading to potential damage and prolonged processing times.
Innovation Solution
A feed mixer with a multi-speed transmission and a control system that uses torque sensors to automatically adjust gear shifts based on detected torque demand and vital operating conditions, allowing for both automatic and semi-manual operation, and preventing drive system damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual gear shifting is used, then device complexity is reduced, but productivity decreases due to operator intervention requirements and processing time loss
Solution Approach 1:
The transmission system automatically monitors torque demand through sensors and shifts gears without operator intervention. The control system self-regulates by detecting torque levels and commanding appropriate gear changes, eliminating the need for manual operation while maintaining optimal mixing efficiency.
Solution Approach 2:
The system incorporates torque sensors that continuously monitor the torque demand on the transmission. This feedback is processed by the control system, which automatically adjusts gear selection based on real-time torque levels, enabling responsive and efficient transmission control.
2Measurement precision
If weight-based torque calculation is used, then device complexity is reduced, but measurement precision deteriorates due to unreliable torque indication when mixing ingredients with varying densities
Solution Approach 1:
The patent replaces weight-based torque calculation with direct mechanical torque sensing using torque sensors. These sensors physically measure the torque demand on the transmission, providing accurate real-time data regardless of ingredient density variations, thereby eliminating the limitations of indirect weight-based estimation.
Solution Approach 2:
Torque sensors serve as intermediary devices that directly measure torque demand between the transmission and mixing elements. This intermediary measurement system provides precise torque data without requiring assumptions about ingredient properties, enabling accurate transmission control.
3Loss of time
If operator manual shifting is required, then ease of operation is maintained through simple controls, but loss of time increases due to stopping PTO shaft and manual intervention
Solution Approach 1:
The transmission system performs automatic gear shifting without requiring operator intervention. The control system continuously monitors torque demand and automatically commands gear changes, eliminating the time lost to manual stopping and shifting operations while maintaining optimal performance.
Solution Approach 2:
The automatic transmission control enables continuous mixing operation without interruptions for gear shifting. The system maintains continuous torque monitoring and performs gear changes seamlessly, eliminating downtime and keeping the mixing process continuously productive.
4Reliability
If weight in mixing chamber is used as control input, then device complexity is reduced, but reliability deteriorates because weight is not a reliable indication of loading on drive components
Solution Approach 1:
The system replaces indirect weight-based control with direct mechanical torque sensing. Torque sensors provide accurate real-time measurement of actual loading on drive components, enabling reliable protection and control that directly reflects the mechanical stress on the transmission system.
Solution Approach 2:
The control system incorporates continuous torque feedback from sensors mounted on the transmission. This feedback provides accurate information about actual drive component loading, enabling reliable automatic adjustment and protection compared to indirect weight-based estimation.
Data Source
AI summary
A feed mixer apparatus that includes a mixing chamber for receiving feed, and having a mixing element situated therein for mixing the feed, a transmission having a plurality of gears and connected with a mixing element, a drive system having a plurality of drive system components, including the transmission, a torque sensor interconnected with at least one drive system component, a control unit having a display and a plurality of user inputs, wherein the control unit is in at least indirect communication with the transmission and the torque sensor, and wherein the control unit receives a plurality of outputs from one or more of the transmission and torque sensor, and based at least in part on the plurality of outputs, provides an output command to effectuate a gear change in the transmission.