Vibration Conveyor Acceleration Sensor Control
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Solution Overview
Problem
Vibration feeders face challenges in precise regulation of mass flow and high costs due to the need for expensive sensors and extensive cabling for explosion protection and electromagnetic compatibility, especially when the control unit is remote from the vibration feeder.
Innovation Solution
Incorporating an acceleration sensor on the vibration feeder itself to regulate the vibration drive using acceleration as a variable, ensuring local explosion protection and electromagnetic compatibility, and eliminating the need for expensive sensors for vibratory movement detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If the control unit is placed remotely from the vibration feeder to centralize control, then the production line control is improved, but expensive cable connections for explosion protection and electromagnetic compatibility are required
Solution Approach 1:
The control unit is integrated directly into the vibration feeder housing, merging the control function with the vibration generator. This eliminates the need for separate control units and expensive cable connections while maintaining centralized control capability through the production line control system.
Solution Approach 2:
A wireless communication interface serves as an intermediary between the production line control system and the vibration feeder control unit. This allows centralized control without requiring physical cable connections, thereby avoiding explosion protection and electromagnetic compatibility cable requirements.
2Measurement precision
If a sensor for detecting the vibratory movement of the carrier arrangement is used, then the mass flow regulation is achieved, but expensive sensors and extensive cabling for explosion protection are required
Solution Approach 1:
The vibration feeder uses its own inherent vibratory movement characteristics as the sensing mechanism. The control unit monitors the electrical characteristics of the vibration drive motor itself, which naturally reflect the load conditions and mass flow, eliminating the need for separate expensive sensors.
Solution Approach 2:
The patent replaces mechanical vibration sensors with an electrical monitoring system that detects mass flow through analysis of the vibration drive's electrical parameters. This substitution eliminates mechanical sensors and their associated cabling requirements while maintaining measurement precision.
3Device complexity
If the control unit is integrated locally on the vibration feeder, then explosion protection and electromagnetic compatibility costs are reduced, but the control distance from the production line control increases
Solution Approach 1:
A wireless communication interface acts as an intermediary between the locally integrated control unit and the remote production line control system. This enables the control unit to be positioned optimally for explosion protection and electromagnetic compatibility while maintaining communication capability over the required distance.
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 approach allows for precise and cost-effective regulation of mass flow with improved explosion protection and electromagnetic compatibility, reducing the complexity and expense of cabling while ensuring efficient operation within the resonance frequency for maximum efficiency.
Implementation Method 1
an acceleration sensor (27) arranged on it, wherein, when the vibration feeder (25) is in operation, the acceleration sensor (27) detects the actual acceleration of the drive unit (4)
Implementation Method 2
a vibration drive (10) for the carrier arrangement (5)
Implementation Method 3
the drive unit (4) also vibrates due to the reaction forces of the driven carrier arrangement (5)
Data Source
AI summary
The vibration feeder has a drive unit comprising a vibration drive, a carrier arrangement comprising a feeding element for the material to be conveyed and a control for the vibration drive, wherein an acceleration sensor is arranged on the drive unit, which when the vibration feeder is operating, detects the actual acceleration of the drive unit, and wherein the control is configured to use the actual acceleration signal of the acceleration sensor for generating a regulating variable for the vibration drive such that the carrier arrangement vibrates essentially within its resonance frequency (fres). This makes it possible, during operation, to detect the acceleration of a drive unit of the vibration feeder and to generate therefrom a regulating variable for a vibration drive such that a carrier arrangement of the vibration feeder vibrates closer to its resonance frequency (fres) or is brought back again to the same. In addition the inventive control may be used to also regulate the amplitude of the carrier arrangement and the associated mass flow m to a required value.