Combination Weigher Hopper Control for Over-scaling Prevention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In combination weighing devices, frequent over-scaling occurs when no hopper combination meets the correct weight range, leading to reduced utilization rates due to the need to discharge articles from over-scaling hoppers, which can result in fewer available hoppers for calculation, further preventing the finding of a valid combination.
Innovation Solution
A combination weighing device with a conveyance unit, hoppers for temporary retention and discharge, and a control unit that switches between two modes: one where additional articles are supplied to selected hoppers and another where articles from potentially over-scaling hoppers are discharged, to prevent over-scaling and maintain utilization rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If additional articles are supplied to selected hoppers when no combination falls within the correct weight range, then the target weight can be achieved, but over-scaling occurs where the weight value in one hopper exceeds the correct weight range
Solution Approach 1:
The patent applies dynamics by making the hopper configuration adaptable - hoppers can be dynamically selected and configured based on real-time weight measurements. The system transitions from a static fixed hopper arrangement to a dynamic selection process where the control unit determines which hoppers to use based on current article weights, allowing the system to optimize for precision while avoiding over-scaling.
Solution Approach 2:
The patent changes the parameter of hopper capacity utilization by selecting different combinations of hoppers based on measured weight values. Instead of always using the same hoppers or simply adding articles to reach the target weight, the system varies which hoppers are activated and how their capacities are utilized, adjusting parameters to prevent any single hopper from exceeding the correct weight range.
2Reliability
If articles in hoppers with over-scaling are discharged from the system to avoid drop in utilization rate, then over-scaling is prevented, but the number of available hoppers for combination calculation is reduced
Solution Approach 1:
The patent applies preliminary action by performing combination calculations using the control unit before articles are discharged or additional articles are supplied. The system calculates which hopper combinations will achieve the target weight within the correct range in advance, preventing over-scaling before it occurs rather than reacting to it afterward. This preliminary calculation ensures that all hoppers remain available for use.
Solution Approach 2:
The system uses feedback from weight measurements to guide hopper selection and article distribution. The control unit receives feedback on the weight values in each hopper and uses this information to determine the optimal combination of hoppers to achieve the target weight without over-scaling, thereby maintaining both utilization rate and hopper availability.
3Area of stationary object
If the number of weighing hoppers is small due to production space issues, then the device fits production space constraints, but the number of hopper combinations is limited making it harder to find valid combinations
Solution Approach 1:
The patent applies dynamics by implementing a control unit that dynamically selects and calculates optimal hopper combinations based on real-time weight measurements. Even with a small fixed number of hoppers, the system adapts by intelligently determining which combinations will achieve the target weight within the correct range, effectively increasing the versatility of the limited hopper configuration.
Solution Approach 2:
The patent changes parameters by using the control unit to optimize the utilization of each hopper's capacity based on measured weight values. The system adjusts which hoppers are activated and how their capacities are combined to achieve the target weight, maximizing the effectiveness of the limited number of hoppers available in the constrained production space.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A combination weighing device (1) includes: a plurality of hoppers (5, 6) configured to temporarily retain the articles which are conveyed by the conveyance unit, and then discharge the articles downstream; an acquisition unit (50) configured to acquire weight values of the articles retained in each of the hoppers; and a control unit (30) configured to specify at least one of the hoppers from which the articles are discharged on the basis of the weight values and a target range which is preset. The combination weighing device (1) operates such that the articles are additionally supplied to a selected hopper while the articles retained in the hopper are left as is in the first mode, and operates such that, instead of the articles being additionally supplied to a selected hopper, the articles retained in the selected hopper are discharged to the outside, and the articles are newly supplied to the selected hopper in the second mode.