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Controlling method and a measuring mixer for liquids and powders    
United States Patent4830508   
Link to this pagehttp://www.wikipatents.com/4830508.html
Inventor(s)Higuchi; Noboru (Kanagawa, JP); Matsui; Keizo (Kanagawa, JP); Kobayashi; Chuzo (Kanagawa, JP); Ohnishi; Hiroshi (Kanagawa, JP); Yamaguchi; Shigeru (Kanagawa, JP)
AbstractA measuring mixer for use with either liquids or powders in which different supply systems supply different stock liquids or powders to a receiving container from supply containers. A continuously variable flow regulator is associated with each supply container. The cumulative weight of the receiving container is measured and compared with a target weight. Then a computation section calculates a desired flow rate based upon both the deviation from the target weight and a time variation thereof. This calculation is preferably done according to fuzzy inference. The desired flow rate is then used to control a selected one of the flow regulators so that the measurement is sequentially performed between supply systems. Optionally, the receiving container can be movable between the different supply systems.
   














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Inventor     Higuchi; Noboru (Kanagawa, JP); Matsui; Keizo (Kanagawa, JP); Kobayashi; Chuzo (Kanagawa, JP); Ohnishi; Hiroshi (Kanagawa, JP); Yamaguchi; Shigeru (Kanagawa, JP)
Owner/Assignee     Fuji Photo Film Co., Ltd. (Kanagawa, JP)
Patent assignment
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Publication Date     May 16, 1989
Application Number     07/189,099
PAIR File History     Application Data   Transaction History
Image File Wrapper   Patent Term   Fees
Litigation
Filing Date     May 2, 1988
US Classification     366/141 137/88 222/56 366/18 366/20 366/21 366/152.1 366/154.2 366/156.2 366/182.4 706/900
Int'l Classification     B01F 015/04 G05D 011/00
Examiner     Jenkins; Robert W.
Assistant Examiner    
Attorney/Law Firm     Sughrue, Mion, Zinn, Macpeak, and Seas
Address
Parent Case    
Priority Data     May 01, 1987[JP]62-106413 May 01, 1987[JP]62-106414 May 01, 1987[JP]62-106415 May 07, 1987[JP]62-109686 May 08, 1987[JP]62-110857
USPTO Field of Search     366/18 366/16 366/17 366/19 366/20 366/21 366/8 366/141 366/152 366/153 366/160 366/161 366/162 137/88 222/56 222/55 222/77
Patent Tags     controlling measuring mixer liquids powders
   
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What is claimed is:

1. A flowing material measuring device, comprising:

a supply container containing a flowable material;

a flow regulator connected to an outlet of said flow container for regulating a flow of said flowable material in at least three non-zero flow quantities;

a receiving container receiving said flowable material from said flow regulator;

a detector associated with said receiving container for measuring a quantity of material received by said receiving container;

a control unit receiving an output of said detector and including means for deriving a deviation between said measured quantity and a target value and a time variation of said deviation and further including means for setting a flow quantity in accordance with said deviation and said time variation of said deviation, said set flow quantity controlling said flow regulator.

2. A flowing material measuring device as recited in claim 1, wherein said setting means operates with fuzzy inference upon said deviation and said time variation.

3. A flowing material measuring device as recited in claim 1, wherein said detector measures a weight of said receiving container.

4. A flowing material measuring device as recited in claim 1, wherein said flowable material is a liquid and said flow regulators are opening control valves.

5. A flowing material measuring device as recited in claim 1, wherein said flowable material is a powder and said detector measures a weight of said receiving container.

6. A flowing material measuring device as recited in claim 1, further comprising a stop gate disposed in a transport path of said flowable material between said flow regulator and said receiving container, said setting means controlling said stop gate.

7. A flowing material measuring device as recited in claim 1 wherein said flow regulator is substantially continuously variable in regulating said flow of said flowable material.

8. A method of measuring a flowable material, comprising the steps of:

regulating a flow rate of a quantity of a flowable material into a receiving container according to at least three non-zero flow rates;

measuring a quantity of material received in said receiving container;

comparing said measured quantity with a target quantity to produce a deviation value;

computing a time variation of said deviation value; and

setting said regulated flow rate in response to said comparing and computing steps.

9. A method as recited in claim 8, wherein said setting step operates with fuzzy inference rules upon said deviation and said time variation.

10. A flowing material measuring mixer, comprising:

at least two supply systems each comprising a supply container containing a respective flowable material and a flow velocity regulator connected to an outlet of said supply container for varying a flow of said flowable material therethrough in at least three non-zero increments;

a receiving container at least connectable to outlets of each of said flow velocity, regulators for receiving said flowable materials from each of said supply systems;

a measuring device associated with said receiving container for measuring a quantity of any of said flowable materials received into said receiving container;

a measurement control unit receiving a target quantity and an output of said measuring device and deriving a deviation therebetween and including means for computing a desired flow quantity in accordance with said deviation; and

means for selectively applying said desired flow quantity to a selected one of said flow velocity controllers.

11. A flowing material measuring mixer as recited in claim 10, wherein said applying means comprises a switch selectively switching signals from said measurement control unit to said flow regulators.

12. A flowing material measuring mixer as recited in claim 11, wherein said computing means operates according to fuzzy inference rules on said deviation and said time variation.

13. A flowing material measuring mixer as recited in claim 10, wherein said measurement control includes means for deriving a time variation of said deviation and wherein said computing means computes said desired flow additionally in accordance with said time variation.

14. A flowing material measuring mixer as recited in claim 10, wherein each of said flow velocity regulators varies said flow in substantially continuous increments.

15. A flowing material measuring mixer as recited in claim 10, further comprising reaction means associated with said receiving container for promoting reactions between a plurality of said flowable materials received in said receiving container.

16. A flowing material measuring mixer as recited in claim 10, wherein said flowable materials are liquids and said flow regulators are opening control valves.

17. A flowing material measuring mixer as recited in claim 10, wherein said flowable materials are powders and said measuring device measures a weight of said receiving container.

18. A flowing material measuring mixer as recited in claim 17, wherein said flow regulators are selected from a screw feeder, an opening degree damper or a rotary device.

19. A flowing material measuring mixer as recited in claim 10, further comprising a further measuring device associated with one of said supply containers for measuring an amount of said flowable material contained therein said computing means further computing said desired flow rate in accordance with an output of said further measuring device.

20. A flowing material measuring mixer as recited in claim 19 further comprising an adjusting container receiving said flowable materials from said receiving container and reaction means associated with said adjusting container for promoting mixing of said flowable materials in said adjusting container.

21. A flowing material measuring mixer as recited in claim 20, wherein said adjusting container receives a mixture of said flowable materials from said receiving container.

22. A flowing material measuring mixer as recited in claim 21, wherein said flowable materials are powders and further comprising liquid supply means connected to said adjusting container.

23. A flowing material measuring mixer- as recited in claim 10, wherein each of said supply systems further comprises an outlet port downstream of said flow velocity regulators and further comprising a moving device for moving said receiving container between said outlets ports of different ones of said supply systems.

24. A flowing material measuring mixer as recited in claim 23, wherein said flowable materials are powders.

25. A flowing material measuring mixer as recited in claim 23, wherein said flowable materials are liquids.

26. A flowing material measuring mixer as recited in claim 23, wherein said moving device is an unmanned carriage for lifting said receiving container.

27. A flowing material measuring mixer as recited in claim 23, wherein said moving device comprises a set of wheels attached to said receiving container.

28. A flowing material measuring mixer as recited in claim 23, further comprising a reaction station comprising reaction means operable with said receiving container and wherein said moving device moves said receiving container between said outlets ports and said reaction station.

29. A flowing material measuring mixer as recited in claim 23, further comprising a reception container comprising a receiving port and wherein said moving device moves said receiving container between said outlet ports and said receiving port.
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DESCRIPTION

1. Field of the Invention

The present invention relates to a liquid or powder measurement controlling method and an apparatus thereof. More particularly, the invention relates to a liquid/powder measurement controlling method and an apparatus which are intended to have an improved measuring accuracy, an expanded measuring range and a constant measuring time. These objects are obtained by sequentially varying the flow velocities of substances to be measured on the basis of an observed quantity obtained during the measurement.

The present invention also relates to a liquid or powder measuring mixer for producing a new mixed liquid or powder by intermixing a variety of stock liquids or powders after measuring these liquids or powders.

2. Background Art

A liquid can be measured by the use of a variety of systems, such as a weight system (e.g., load cell), a pressure system. (e.g., differential pressure transmitter), a capacity system (e.g., oval flowmeter) and so on. For the measurement of a pulverulent body or fine powder, there is known the weight system which mainly employs a load cell or the like.

In all these systems, however, the measurement control is performed on the basis that the flow velocity is constant. A closed loop measurement controlling system in which the flow velocities are successively varied does not come under the above-described concept.

For the purpose of enhancing the measuring accuracy, the following techniques have in the past been utilized.

In a first technique, as described, for example, in Japanese Patent Publication No. 148019/1981, the flow velocity changes between two stages and the measurement is made by a change-over to a slow flow velocity in the vicinity of the target value.

In a first example of the first technique two kinds of devices have different flow velocities. The change-over between the two is executed when the deviation between the target value and the actual measurement value reaches a given conditional value. In a second example of the first technique, a single device has the capability to change-over the flow velocity to two kinds of fixed conditions. The change-over is executed, as in the first example, when the deviation reaches the given conditional value. In a third example, based on the concepts of the first and second examples, the conditional value for commanding the change-over is modified from the previous measurement result by adding a learning function identified as a software function.

In a second technique, such as disclosed in Japanese Patent Laid-Open Application No. 29114/1982, there is an inflow level (also referred to as a head quantity) used as a measurement halting condition. The measurement technique is arranged such that the measurement is previously stopped in anticipation of the inflow level. In a first example of the second technique, the measurement stops when the deviation between the target value and the actual measurement value reaches the given condition. In a second example, the situation is almost the same as that in the third example of the first technique. However, the conditional value for commanding the halt of measurement is modified by an arithmetic calculation based on the preceding actual measurement result.

In order to attain highly accurate measurement, the measuring device applied to the liquid or powder measuring mixer has heretofore been confined to such a type that the flow velocity of the liquid or powder is limited and generally fixed. The measuring device of such a type that the flow velocity is variable has not been seen so far.

Where liquids or powders are fed from a plurality of supply containers to another container, a conventional type of liquid or powder measuring mixer is required to have the measuring devices attached to the individual supply containers.

For instance, when a capacity measuring system is used, as illustrated in FIG. 1, two separate measuring devices are employed for the two kinds of liquids or powders. There are required two control units with separate control functions for two loops to predictively control the quantities flowing into the mix container.

A "Liquid Adjusting Apparatus" and a "Method of Supplying Liquid" are disclosed in Japanese Patent Laid-Open Application No. 74715/1981 and Japanese Patent Publication No. 163426/1982, respectively. Based on the above-described method and apparatus, the flow rates of the plurality of liquids are sequentially measured by means of a common measuring device. Liquid supply means attached to the respective containers to feed out the liquids are controlled by independent control loops.

Namely, the flow rate of the liquid or powder differs according to the quantity of liquid or powder stocked in the supply container, according to the flow rate characteristics of the valve and according to liquid or powder properties. Hence, a highly precise measurement cannot be expected under the same control.

This situation is the same with a tank measuring system. It is required that actuator stop valves attached to respective systems are controlled by control systems of independent loops.

With a view to achieving a highly accurate measurement, there has been proposed a method of performing change-over between two flow rates in accordance with a predetermined measurement deviation by providing two parallel valves, the flow velocities of which are different from each other. Change-over between the two paths is executed at a predetermined difference between the desired and measured amounts. In this case, however, fulfillment of the control function requires the control of two loops.

The reason why it is said that the control functions of two loops is required is that when making use of a dispersive type control unit, two separate control units are not necessary, because the measuring process can be done in the single control unit. Judging form the number of inputs and outputs and softwares as well, however the two separate control units are required.

Further, there is disclosed in Japanese Patent Laid-Open Application No. 148019/1981 and Japanese Patent Laid-Open Application No. 155412/1981 a control system for adjusting the flow rate of powders or by adjusting a predetermined period at the next measuring cycle by computing a mean flow rate from the total discharge weights of substances to be measured at a given number of previous measuring cycles and from a time required and by further obtaining a deviation between this mean flow rate and a target value.

The flow rate of the powder, however, differs according to residual quantities of the powder within the supply containers, the target value properties of the powder. Hence, the highly accurate measurement cannot be expected under the same control function.

In order to achieve a highly accurate measurement of powders, there is proposed a method (Japanese Patent Laid-Open Publication No. 72015/1982) of effecting a change-over between the two flow rates in accordance with a predetermined measurement deviation. In this case, however, fulfillment of the control functions requires the control of two loops.

However, in the conventional measurement control, the change-over is carried out, as explained above, by making the flow velocity constant or by varying the velocity in two stages. There arise, however, the following problems inherent in the prior art measurement control, because the measurement is fixed within a certain range.

A first problem is a lack of measuring accuracy. A situation arises where the accuracy becomes unreliable due to fluctuations in flow velocity which are caused by disturbances and variations in properties of the substance to be measured, whether it be fluid or powder. In the case of gravity transfer, the fluctuations in flow velocity are created in the measured substance which flows out in accordance with the residual amount. This residual amount is hereinafter in this specification referred to as a head difference of the measured substance disposed in the container on the upper stream side of the measuring point. If the head difference is large, however, the flow velocity is in excess of the certain conditional range, and accuracy is thereby degraded. This fact also results in the restriction of the allowed variation of the head difference. In order to keep the head difference within a predetermined scope, it is strictly required that the measurement be stopped, or alternatively, the container disposed on the upper stream side be properly resupplied with a raw material. This also secondarily increases cost and causes a loss of raw material.

Especially, the fluidity of a hygroscopic powder or of a powder subject to bridging differs, depending on ambient storage conditions. In a system in which the powder is used while being reserved in the supply containers, its fluidity varies according to variations in ambient conditions, for instance, temperature, humidity and vibrations caused by supplementary devices such as a vibrator, an air knocker and so forth which are intended to foster the fluidity. For this reason, flow conditions become different and it follows that the measuring accuracy is degraded. To cope with this degradation, restrictions are imposed for both duration of storage and for the ambient conditions under which the device is installed in order to maintain the measuring accuracy. This, as a result, increases the initial costs and the running costs of the equipment.

A second problem is the restricted measuring range. Since the flow velocity is restricted a ratio of the minimum to the maximum of the measurable measurement value is approximately 1:5. In a 2-stage flow velocity system, the ratio is approximately 1:10 at the most. The reason why the measurement range is narrow will be explained as follows. Even if the measurement is halted, an extra amount of the material continues to flow in because of a delay of response of the system. This extra inflow quantity is determined by the flow velocity. Hence if the target value is small, the extra inflow quantity exceeds a guaranteed accuracy, and it follows that the measuring range is restricted. Alternatively, the allowable extra inflow quantity can be controlled by narrowing the measuring range under the condition that the flow velocity is constant. Where the same kind of liquid or powder is measured, multiple measuring devices each having their proper measuring range are needed but this multiplicity augments the number of devices. In production plants which deal with a wide variety of materials, there are some measuring systems of the type in which the ratio within the measuring range is about 1:100 at most in the case of the same raw material. Therefore, it is necessary to select the measuring devices within a range of target values.

A third problem is the lengthy measuring time. A measuring time is contingent on the target value. When the target value is small the measuring time is short, and vice versa. When the target value is small, an operating time of the system is subject to scatter, whereby the measuring accuracy is not assured. This also leads to a narrower measurement range. Consequently, multiple appropriate measuring devices are needed in accordance with the required measurement values, thereby increasing the number of devices In the light of the entire system for producing a new mixture by combining multiple already-measured substance, the production capability is determined by the measuring time. Especially in a pipeless transfer production system the carrying capability is limited

The above-described defects further results in economic disadvantages in terms of setting up the equipment for the process. Such is the prior art arrangement that a multiplicity of independently controlled measuring devices are provided in accordance with the target values and a separate measuring device has to be prepared for every raw material or to provide an optimum measuring time because of the restriction of the production capability. Also, a separate measuring device is required for each supply container. Hence, the system becomes complex and a large number of measuring devices have to be available.

The situation is the same with a liquid tank or powder hopper measuring system. It is required that stop valves attached to actuators in individual systems be controlled by independent loop control systems (See Japanese Patent Laid-Open Nos. 29114/1982, 163426/1983 and 74715/1981).

The prior art powder measuring mixer is equipped with the measuring devices attached to the individual supply containers in order to feed the powders from the receiving container (See Japanese Patent Application Laid-Open Nos. 148019/1981, 155412/1981 and 72015/1982).

SUMMARY OF THE INVENTION

Accordingly, in view of the above difficulties, it is an object of the present invention to provide a measurement controlling apparatus and method for liquids and powders which is capable of attaining a highly accurate measurement without being subject to fluctuations in flow velocity that are produced due to disturbances and variations both in the viscosity of the liquid or the fluidity of the powder; of ensuring a wide measurement range; and of performing the measurement within a short period of time without depending upon the magnitude of a target value.

To this end, according to one aspect of the invention, there is provided a measurement controlling apparatus for accomplishing this measurement controlling method.

The precise measurement controlling apparatus which constitutes the system brings about a reduction in the number of mechanical elements, enhances the capability of the equipment and decreases the loss of raw materials.

In accordance with this liquid and powder measuring mixer the system is constructed by employing a measurement control unit for performing the measurement in a short time regardless of the magnitude of a target value. Thereby, the equipment is simplified, the production capability is augmented, and a loss of raw materials is following significant economic benefits:

(1) a decrease in initial cost which is derived from a reduction in the number of devices,

(2) a decrease in the required maintenance which is attributed to the drop in the number of devices,

(3) a decreased failure rate which is associated with improved reliability and the reduction in the number of devices, and

(4) a decrease in running cost which is due to the drop in loss of the raw materials.

The above-described object is accomplished by a liquid or powder measuring mixer in which a small number of measurement control units momentarily vary the flow velocity under closed loop control when measuring a liquid or powder. The liquid or powder measuring mixer according to the present invention is composed of the following components.

(1) Supply container (or tank): This container is designed for storing the liquid or powder to be measured and has a capacity suited to the scale of production. In accordance with the, present invention, there is no limit on the residual quantity of the material remaining in the container. Theoretically, the measurement is practicable up to a zero residual quantity. There is no final influence caused by values of liquid material property values (e.g., viscosity for a liquid or granularity for a powder). Any kind of liquid or powder can be measured down to zero residual quantity as long as the liquid or powder flows.

(2) Flow velocity control unit: The flow velocity control unit has several flow velocity controllers, the number of which corresponds to the number of the supply containers. For a liquid mixer, the flow velocity controllers are opening control valves. The opening control valves are intended to vary the flow velocity by changing a degree of opening thereof. For a powder mixer, the flow velocity controllers may be a screw feeder or a damper. In the screw feeder, the flow is controlled by issuing a rotational frequency command. In the damper, the flow is varied by changing the opening degree. A driving mechanism for the valves and other flow controllers involves the use of, for instance, an AC servo motor.

(3) Change-over device: This change-over device helps a driving control unit control the plurality of flow velocity controllers. If a driving control unit is provided for every opening control valve or flow velocity controller, the change-over device is not required. In some cases, however, the change-over device is provided to reduce the costs.

(4) Measuring device: One measuring device is provided on the side of the liquid or powder receiving container and measures the liquid or powder sent from the plurality of supply containers. The measuring device performs cumulative measurement of the weights of the mixed liquid or powder. A tank or hopper measuring system employs a load cell a differential pressure transmitter or a level gauge. An additional measuring device may be fitted to a supply container, or alternatively the supply container is mounted on a measuring board.

(5) The measurement control unit accomplishes precise closed loop measurement control for varying the flow velocity and serves to measure the respective liquids or powders with the aid of a single measuring device. The plurality of liquids or powders can be measured by the single measuring device in the same container so the number of devices can be reduced. The change-over device is part of the measurement control unit.

(6) Liquid or powder receiving container (or tank): This container has a capacity adapted to the scale of production. Mixable liquids or powders are cumulatively measured. If cleaning is performed for every transfer of the measured liquid, the measurement can independently be done in the same container even in an unmixed state. Stirring and mixing may be conducted in this container.

(7) Moving device: The moving device is designed for carrying the liquid or powder receiving container. The moving device involves the use of an unmanned carriage, a conveyor and so on. In connection with a carrying mode, the liquid or powder receiving container itself may be movable, or alternatively this movable function may be provided by a separate structure.

The fundamental components of the present invention have been described above but it is a basic concept that is employs a closed loop measurement control unit for varying the flow velocity. In some cases, a wide variety of other supplementary devices are provided.

For example, individual containers for liquids may be equipped with spray bowls or the like for cleaning and change-over valves may be interposed in the pipes. The respective liquid containers may be provided with stirrer for mixing. Furthermore, hot water from a thermostatic oven may be circulated for maintaining the temperature.

There are a wide variety of flow velocity controllers for varying the flow velocity of a powder. The flow velocity controller may be a rotary system in which a screw feeder changes the flow in response to a command of rotational frequency. Another system, usable if the powder is highly fluid, varies the flow by changing the opening degree of a damper in response to a positional command. In addition, a shutter gate may be used as a flow stopping type.

The condition that the flow velocity remain constant is the fundamental factor which causes drawbacks inherent in the conventional measuring device. In the measurement controlling method, however, the flow velocity is variable under closed loop control, thereby attaining a highly accurate measurement subject to no influence of fluctuations in flow velocity which are caused by disturbances.

It further attains a wide range of measurement and a short time measurement does not depend on the magnitude of the target value.

To accomplish the above, the measurement controlling apparatus is characterized by the following system and components including a control system, a detector and an operating device.

The control system may be defined as a non-linear type when modelling is considered. Therefore, the actualization cannot easily be made by a prior art simple PID control system.

To cope with this, an optimum manipulated variable is computed from a deviation between the target value and the actual measurement value and also from an observed quantity of the time variation of the deviation under fuzzy control or learning control or optimum control. Subsequently, the measurement control is accomplished by sequentially changing the flow velocity to an optimum state in a continuous and descrete manner.

The detector serves to observe momentary variations in the measured value. It is satisfactory that the detector is able to observe the measured values of a load cell, a differential pressure transmitter and so forth. However, the measuring range is contingent upon the static accuracy of the detector.

The operating device is intended to vary the flow velocity. The operating device is composed of mechanical parts and electric drivers although the driving may be performed with a fluid like air or oil.

In the case of a liquid, a general practice is that the flow velocity is varied by varying an opening. In this case, a valve to be used may involve well known control valves assuming different configurations or a novel valve having a notch-groove in its valve peripheral surface in a valve-driving direction so that a flow rate can be varied. It is sufficient for the well known valves to have common flow rate characteristics except for quick opening. A satisfactory arrangement of a valve is that the flow velocity successively varies from zero. There are many kinds of other methods, but any apparatus capable of changing the flow velocity from zero may be applicable.

Additionally, a moving device may be provided for moving the liquid or powder receiving container is provided. The liquid or powder receiving container can be carried by the moving device. (1) Hence, the liquid or powder received from all the supply containers and are measured by using no fixed pipes or ducts and consequently, there is created versatility in equipment by decreasing the number of the receiving containers. In the case of producing multiple liquids or powder bodies, mechanical play in the equipment on the part of the receiving containers can be eliminated. Besides, it is feasible to cope with changing processes while still restricting an increase in the number of equipment to the utmost. (2) It is possible to accelerate the measuring cycle by moving the receiving container so that a change with passage of time can be minimized. (3) A stirrer can be fitted to the container for receiving the liquid or powder transferred from the supply containers, thus constituting an adjusting or reaction tank. (4) For a liquid, there is no need for a connecting pipe nor for its cleaning.

In a commonly used method in handling powder, a screw feeder varies the amount of transfer of the powder by changing a rotational frequency of a motor.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram illustrating a conventional measuring mixer.

FIG. 2 is a diagram illustrating a liquid measuring device applied to one embodiment of the present invention.

FIG. 3 is a control block diagram illustrating a control method according to the present invention.

FIG. 4 is a measuring characteristic diagram showing results of an experiment conducted in accordance with the present invention.

FIG. 5 is a table illustrating measurement characteristics.

FIG. 6 is a block diagram of a dual liquid measuring device, illustrating one embodiment of the present invention.

FIGS. 7 and 8 are flow-rate characteristic diagrams of valves applied to an experimental measurement which is conducted by employing the device depicted in FIG. 6. FIG. 7 showing a large flow velocity type valve and FIG. 8 showing a small flow velocity type valve.

FIGS. 9 and 10 are diagrams, which correspond to FIGS. 7 and 8, showing measurement results of the experiment.

FIG. 11 is a control block diagram illustrating a multiple liquid measuring mixer according to the present invention.

FIG. 12 is a control block diagram illustrating a variant form of the present invention for a liquid mixer.

FIG. 13 is a block diagram of a multiple powder body measuring mixer, illustrating one embodiment of the present invention.

FIG. 14 is a control block diagram illustrating the measuring mixer depicted in FIG. 13.

FIG. 15 is a flow-rate characteristic diagram when employing a screw feeder for two kinds of powders.

FIGS. 16 to 18 are flow-rate characteristic diagrams illustrating results of experiments conducted in accordance with the present invention for powders.

FIG. 19 is a block diagram of the powder measuring mixer, illustrating a variant form of the present invention.

FIG. 20 is a control block diagram illustrating the measuring device depicted in FIG. 19.

FIG. 21 is a block diagram showing one example of a liquid measuring mixer.

FIG. 22 illustrates one example of a fixed powder measuring mixer.

FIG. 23 is a block diagram illustrating one embodiment of a movable liquid measuring mixer according to the present invention.

FIGS. 24 and 25 are block diagrams illustrating two movable embodiments of the liquid measuring mixer of the present invention.

FIG. 26 is a block diagram illustrating one embodiment of a movable powder measuring mixer according to the present invention.

FIG. 27 is a block diagram illustrating closed loop control relative to the embodiment of FIG. 26.

FIGS. 28, 29, 30 and 31 are diagrams used for explaining fuzzy control.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The preferred embodiments of the present invention will hereinafter be described with reference to the accompanying drawings.

Turning now to FIG. 2, there is illustrated a liquid measuring device, which is one embodiment of the present invention. The description will concentrate on the case where a material filling a supply tank 1 provided on the upstream side is transferred to a measurement tank 2 on the downstream side, and a weight of the liquid is measured by a load cell 4 attached to the measurement tank 2.

A drain valve (DRV) 9 including a flow control valve (FCV) 7 serving as an operating device for varying the flow velocity, a stop valve (SRV) 8 and a cleaning/effluent valve (CVD) 10 are sequentially arrange on a piping path between the supply and measurement tanks 1 and 2. The measurement tank 2 provided on the downstream side is equipped with the load cell 4 serving as a detector for measuring the weight of the substance to be measured. The load cell 4 is connected through a load cell amplifier 5 to a measurement control unit 3. The measurement control unit 3 is connected to a servo driver 6 and the flow control valve which constitutes the operating device.

The measurement of the substance by the above liquid measuring device is initiated by setting a target value to the measurement control unit 3 and further by changing over the drain valve 9 and the cleaning/effluent valve 10 to the path to the measurement tank 2. The target value includes both the weight of new material to be measured and the previous weight of the measurement tank 2. That is, a cumulative weight measurement is performed. Immediately when an indication of starting the measurement is given by the measurement control unit 3, the stop valve 8 opens. Then, a positional command is transmitted from the measurement control unit 3 to the servo driver 6 so the the flow control valve 7 is set to a predetermined degree of opening. A valve port of the flow control valve 7 is set in a specified position by driving its servo motor, thereby controlling its degree of opening. As a result, a flow of the raw material is caused. Then, the raw material in the supply tank 1 begins to be transferred to the measurement tank 2.

The load cell of the tank 2 detects the weight of the thus transferred raw material and feeds back the value through the load cell amplifier 5 to the measurement control unit 3.

The measurement control unit 3 computes both a deviation between the target value and the measured weight value and also a time-variation of this deviation. It further arithmetically obtains a valve opening degree command (positional command) by which the flow velocity is set appropriately at the next control cycle under fuzzy control or optimum control or learning control. At the next control cycle, a new opening degree command (positional command) is issued to the flow control valve 7, thereby varying the flow velocity. A discussion of fuzzy control will be deferred until the end of this patent.

As discussed above, the degree of opening of the flow control valve 7 is controlled in a closed loop (FIG. 3) at the prescribed control cycle on the basis of the observed quantity of the load cell 4. In consequence, the flow velocity is successively and separately controlled at every predetermined interval.

When the observed quantity is approximately equal to the target value, and when the measurement deviation decreases the flow control valve 7 closes its opening, resulting in a very small flow velocity. Hence, an inflow quantity after stopping the measurement diminishes, and the measuring accuracy is improved without being dependent upon the fluctuations in flow velocity that are caused by a disturbance of, for instance, a head difference.

In the measurement control unit 3 according to the present invention, the operation of the flow control valve 7 is changed to achieve the target value within a measuring range. The measurement can be conducted by the same measuring device irrespective of the magnitude of the target value, resulting in an expansion of the measuring range. This expansion should, however, be within a static accuracy of the detector. Besides, the operating pattern of the flow control valve 7 varies within the measuring time, and the measurement can be performed within the same short period of time regardless of the magnitude of the target value.

EXAMPLE 1

FIGS. 4 and 5 in combination show results of an experiment carried out for verifying the above-described phenomenon.

The measuring device on which these results were achieved is capable of performing 10 kg measurement at maximum, and the accuracy of the load cell is 0.02%. The flow control valve is positionally controlled by the servo motor, and the positional command is generated by the measurement control unit.

FIG. 4 illustrates measurement characteristics obtained when 500 g and 1000 g measurements are made by the same measuring device if a liquid of 1.2 kg is left in the upstream supply tank. The absicissa axis indicates the difference between the target and measured values and the degree of opening of the flow control valve, while the ordinate axis shows the measurement time. As is obvious from the figure, the measurement can be effected by the same measuring device irrespective of magnitude of the target value. Therefore, the measuring range is expanded. As a matter of course, a shift in valve opening differs, but it can be observed that the measuring time is almost the same irrespective of magnitude of the target value.

FIG. 5 shows the relation between the measurement accuracy and the measurement time with respect to the target value. Note that the measurement accuracy is obtained by measuring the outflowing liquid with another weight measuring device.

In the case of the 10 kg measurement, the measurement time amounts to approximately 130 sec., and the measurement accuracy is .+-.0.5 g. An accuracy of .+-.1.0% is obtained over a measuring range of 1:100.

The flow velocity varies according to the residual quantity of material remaining in the tank. However, even when initiating the measurement from a different level of residual material, the measuring accuracy and the measuring time do not change. It can be confirmed that there is no influence of fluctuations in flow velocity.

The above-described embodiment has exhibited a positive measuring system for measuring the liquid, that is, a system for measuring the liquid that has flown into the measurement tank 2. Also, the drain valve 9 and the cleaning/effluent valve 10 depicted in the figures are auxiliary valves used for cleaning and effluent. In accordance with the present invention, it will readily be assumed that instead of the positive measuring system a negative measuring system may be utilized for measuring the amount of outflowing liquid from the upstream supply tank by providing, as depicted with a broken line in FIG. 2, a detector in the supply tank 1. The detector may be a pressure-type in which the liquid level is measured by, for instance, a level gauge in addition to weight measurement by using a hopper and