Weigh Batching Free Fall Compensation for Accuracy
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Solution Overview
Problem
Existing batch weighing systems face challenges in achieving accuracy due to mid-air material falling onto the weighing platform after the conveyor is deactivated, leading to over-shooting of target weights, and often compromise between speed and accuracy by altering conveyor speeds.
Innovation Solution
A method where free fall weights and conveyor delivery speeds for each ingredient and conveyor are stored in a control system's multi-dimensional data table, allowing for precise adjustments based on formula types, batch sizes, and conveyor variations to optimize weigh-up time and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the conveyor is deactivated after the ingredient weight is determined on the scale, then the weighing process is simple and quick, but the mid-air material falls onto the scale causing over-shooting of target weights
Solution Approach 1:
The conveyor is deactivated before the ingredient weight is fully determined on the scale. This preliminary action allows the mid-air material to continue falling and be accumulated in the total weight, preventing over-shooting of target weights while maintaining a relatively simple control system
Solution Approach 2:
The control system observes the additional weight that fell after the conveying device was deactivated and uses this as a 'free fall' weight stored in memory. This feedback mechanism allows the system to compensate for mid-air material weight in subsequent operations, improving accuracy without significantly increasing complexity
2Productivity
If the conveyor delivers material at a high rate, then the weigh-up speed is improved, but the weighing accuracy deteriorates due to material falling onto the scale
Solution Approach 1:
The conveyor is deactivated in advance of the desired weight being achieved, allowing high-speed delivery during the main weighing phase while the final adjustment accounts for mid-air material weight through the free fall compensation method
Solution Approach 2:
The system changes the conveyor speed parameter dynamically - delivering at high speed during initial weigh-up and then adjusting the deactivation timing based on the approaching target weight, allowing both speed and accuracy to be optimized
3Measurement precision
If the conveyor speed is reduced to improve accuracy, then the weighing accuracy is improved, but the weigh-up time increases
Solution Approach 1:
The conveyor is deactivated before the target weight is reached, allowing the system to use free fall compensation to achieve accurate weighing without requiring prolonged slow-speed delivery, thus reducing overall weigh-up time while maintaining accuracy
Solution Approach 2:
The system uses feedback from the free fall weight observation to adjust subsequent conveying operations, allowing faster weighing speeds in future operations while maintaining accuracy through the pre-calculated compensation factors
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 significantly improves accuracy and speed by allowing tailored free fall weight and speed settings for each ingredient combination, ensuring precise weight measurements while maximizing batch processing efficiency.
Implementation Method 1
the conveying device delivering material to the weigh platform is deactivated by the control system in advance of the desired weight for an ingredient being actually achieved on the scale. This then allows the material in mid air to continue to fall and the weight of this 'mid air' material to be accumulated in the total weight of the batch
Implementation Method 2
the weight of this 'mid air' material to be accumulated in the total weight of the batch
Data Source
AI summary
A method of weigh batching for batch formulae using a number of ingredients conveyed to a weigh hopper by a number of different conveyers. Free fall weights and conveyor delivery speeds for each of the ingredients and each of the conveyors used to convey each ingredient are stored in a control system memory. The stored information is used to prepare batches of various formulated products optimizing both the weigh up time and the ingredient weight accuracy.