This invention relates generally to the field of measurement of particulate materials, and more specifically, to a method and apparatus for weighing a low density particulate in a suspended hopper which data can be used in combination with a feed system to determine material flow rates and hopper refill times.
Solid particulate products, such as grain, animal feed (barley, corn, wheat, and animal by-products), cereals, cat litter, and other particulate materials, are normally converted from bulk material into smaller portions for sale. As part of the packaging process, a bulk quantity of product is placed into a hopper. At the exit end of the hopper is a valve that controls the rate of product flow out of the hopper. To accurately and efficiently fill units of such products, manufacturing technologies have developed techniques to continuously monitor product flow.
In some manufacturing processes, it is either necessary or desirable to suspend the hopper from above, and in this case the strict minimum number of scales or load cells required is one, but, if the hopper must be stationary (as many manufacturing processes require), the hopper requires support against translation and rotation in multiple planes, three supports are usually employed, one for each scale.
Employing multiple scales has a number of disadvantages, such as cost, difficulty of installation, and maintenance. In addition, measurement errors may occur as the result of scale miscalibration, or the malfunction of any scale can affect the entire system.
In view of the foregoing, it would be an improvement in the art to provide a scale system for a suspended hopper that employs a single scale.
The present invention describes several embodiments of a hopper system that employs a single scale, two pivots in place of two of the three scales in three-scale systems of the prior art, and novel arrangement of components which otherwise must be calibrated out of calculations in the prior art systems. Among contemplated embodiments are ones applying flexures in place of pivots, and ones which relocate the valve mechanism such that its center of gravity is aligned directly under the pivots. An excellent cumulative benefit of these embodiments allow the valve mechanism of a typical hopper system to not have to be weighed, so smaller scales are viable for the present invention which could be used with hopper systems of the prior art.
Also, since the flexures take the entire load in the XY plane, the load cell or scale is required to measure in the Z plane only. Because of these benefits, a simple “button” type load cell is viable to be used in embodiments of the present inventions, and it was incapable of enduring such use in suspended hoppers of the prior art. Load cells such as those employed in connection with several embodiments of the present invention, one that do not have to resist side loads, are less expensive and generally more accurate and robust than those which are designed to resist side loadings. The load cell only measures the product and not the heavy fixed load, and a much smoother, higher resolution output is obtained. By employing the derivative of a smooth unfiltered signal, embodiments of the present invention produce a much faster responding signal representative of product flow. An additional benefit of the present system resides in the fact that there is excellent bin level measurement even when the bin is being filled.
Tests on a small hopper of 20 inches in diameter indicated that the center location on fill could easily be held to less than 0.5% on the weight. For continuous flow control, the error is almost insignificant. While a person having ordinary skill in the art would possibly expect that elimination of two scales might cause error in measurement owing to lack of considering a shifting center of mass of a product, practiced embodiments yielded such improvements with respect to resolution of the scale and external force rejection by the flexures as to unexpectedly overwhelm any potential accuracy loss of a non-centered product.
Some of the features and advantages of the present invention having been briefly described, others will appear from the detailed description which follows, when taken in connection with the accompanying drawings in which:
While the present invention will be described more fully hereinafter with reference to the accompanying drawings, in which a particular embodiment is shown, it is to be understood at the outset that a person skilled in the art may modify the invention herein described while still achieving the favorable results of this invention. Accordingly, the description which follows is to be understood as a broad teaching disclosure directed to persons of skill in the appropriate arts and not as limiting upon the present invention.
Referring now to
The valve weight (116) is a downward force applied to the system on the valve mass centerline (100). The distance from the centerlines (108,110) to each of the respective scales is shown as X1 (111) and X2 (112), the respective distances of scale 1 (101) and scale 2 (102), with respect to the product mass centerline (108), and X3 (113) and X4 (114), the respective distances of scale 1(101) and scale 2(102), with respect to the valve mass centerline (110).
The hopper (100), product (105), and valve mechanism (106) are suspended from the supports (103, 104), with the weight of the hopper (100) being hopper weight (117) distributed equally between both scales. The two scales (101, 102) register measurements according to the following:
ΣF is the sum of the vertical forces on the system, SCALE_1 means the weight force (118) at scale 1 (101), and SCALE_2 means the weight force (119) at scale 2 (102), ΣM=0 is the sum of the Moments on the system, where moments are the product of the forces on the system and the respective moment arm distances of each force with respect to a relative point of reference). For clarity, reference numerals do not appears in the following equations, for: Product_weight (115), Scale_1 (118), Scale_2 (119), Valve_Weight (116), and Hopper_weight (117).
ΣF =0 (“setting the sum of the forces equal to zero”) and arrange in terms of Product Weight:
Product_Weight:=SCALE_1+SCALE_2−Valve_Weight−Hopper_Weight EQ 1.1
To determine the exact load on each scale (101,102), we must ΣM=0 (“set the sum of the moments equal to zero”), and substitute into EQ 1.1, to result in EQ 1.2 and 1.3.
The sum of SCALE1(11) and SCALE2(119) therefore give the overall weight of the system, from which known values of Valve_Weight (116) and Hopper_Weight (117) are applied, in order to calculate Product_Weight (115), where Product_Weight (115) is the instant value of the weight (105) of the product in the hopper (106).
Accurate calculation of product weight (115) in the mathematical modeling of the theoretical system shown in
Referring now to
According to EQ 1.3, the valve weight (116) contributes to Scale_1 (118) in proportion to the ratio of X4 (114) to the sum of X3 (113) and X4 (114). With X4 (114) equal to 0, the proportion of valve weight (116) contributed to Scale_1 (118) also collapses to. As such, the entirety of the valve weight (116) is applied to the support (104).
As in
Therefore, substitution into EQ 1.3 of X1=X2 and X4=0 yields:
Re arranging in terms of Product Weight (115) gives:
Product_Weight=2SCALE_1−Hopper_Weight EQ 1.5
In other words, 2× the weight (118) measured by Scale 1 (101), minus the hopper's weight (117) is the product weight (115). Since the valve center of mass (109) has been moved directly under the pivot (200), the valve mechanism (106) does not contribute any fraction of its weight (116) to the force (118) measured at the support (103), as measured by Scale 1 (101).
In contemplated embodiments in which the product center of mass should be in an erroneous position, there are a number of elements that mitigate such error, including:
Referring now to
Whereas
[ΣF=0, ΣMx=0, and ΣMy=0 ] (“setting the sum of the forces and moments equal to zero”):
ΣMx=(d1*sin(a1)*SCALE_1+d2 sin(a2)*SCALE_2+d3 sin(a3)*SCALE_3)=0 EQ 2.1
ΣMy=(d1*cos(a1)*SCALE_1+d2 cos(a2)*SCALE_2+d3 cos(a3)*SCALE_3)=0 EQ 2.2
ΣF=(SCALE_1+SCALE_2+SCALE_3−Product_Weight−Hopper_Weight−Valve_Weight)=0 EQ 2.3
We can thus write the sum of the forces ΣF=0 as the equation:
Product_Weight=SCALE_1+SCALE_2+SCALE_3−Valve_Weight−Hopper_Weight EQ. 2.4.
Then, by including EQS. 2.2 and 2.3 into EQ 2.4, solving for SCALE_3 (310) (the force at Scale 3 (303)) simplifies to:
When the total center of mass (304) is centered in the hopper (300), d1 (305), d2 (306) and d3 (307) are all equal to one another. This represents the condition in which all of the masses would be centered between the scales. In that condition, this 3 scale system can be compared to the 2 scale system of
Substituting (d1=d2=d3) into EQ 2.5, yields:
Compared to EQ 1.2, recognizing that the respective divisors of EQNS 1.2 and 2.6 are the respective number of scales, the equations are essentially equivalent to one another (for their distinct arrangements). The exception is that EQN. 2.6, contains a term for Valve_Weight. To eliminate the term containing Valve_Weight, in order to effect a novel arrangement which alleviates Scale 3 (303) of the burdens of the weight of the valve mechanism (106,
Referring now to
In this position, if d1 (305) of the valve center of mass (109) equals 0, then it would not be weighed. Note, from EQ 2.5, that only two places exist for d1 (305) (or d2 (306)) for this to occur—exactly over Pivot 1 (400) or Pivot 2 (402). The product center of mass (107) is centered with respect to the three supporting objects, the two Pivots (400,401) and Scale 3 (303).
Product_3=3*SCALE_3−3*Hopper_W EQ. 2.7
Note that changes in any of the centers of mass (107) in the Y-plane will be measured as error by Scale 3 (303), whether it is the product center of mass (107), valve center of mass (109) or hopper (along hopper centerline (311)), because since there is no significant force in the Y plane in this two scale embodiment.
Referring now to
Instead of Pivot 1 and 2 (400 and 401 of
A Scale (503) is located on the opposite support (506), similarly located to Scale 3 (303,
In a 3-scale suspended hopper of the prior art (such as
The present embodiment, however, for having Flexures 1 and 2 (501 and 502), it has several properties of a system that has two pivots (
The greater constraint against lateral motions allows embodiments similar to
The embodiment of the present invention of
As a result of these constraints, lateral forces applied to the hopper (500) about the X axis do not contribute to movement of the product, and only X1 (111) and X2 (112) define the product center of mass. Therefore, the equations that describe this measurement, for the embodiment shown in
Without a “Y” term in the equation, any actual movement of the product center of mass in the Y direction does not affect the measurements of weight force (507) actually taken at the Scale (503), and the measurements (which are taken in the Z-direction), will be accurate independent of any shift of the product center of mass (107) in the Y-direction. Compared to the standard three dimensional measurement method of
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