Modeling the Discharge Rate of a Screw Conveyor Considering Hopper–Conveyor Coupling Parameters

Developing a flow rate model for the screw feeder and optimizing discharge performance are crucial for achieving automated intelligent precision feeding. This study constructs a mass flow rate model for screw conveyors, considering the coupled structural parameters of the hopper and screw conveyor. The model is developed using single-factor tests and central composite design (CCD) response surface tests and is validated through actual discharge tests. Results indicate that the discharge rate in the hopper–screw conveyor system is primarily influenced by the screw conveyor itself. Among the structural parameters, the hopper inclination angle and the hopper discharge opening length significantly affect the filling coefficient. Validation tests show an average error of 6.8% between the predicted and simulated mass flow rates and 5.0% with the actual mass flow rate, demonstrating the model’s high precision and accuracy.