Multi-nozzle cooperative intelligent fluidized bed granulating and coating system and method

Abstract

The invention discloses a multi-nozzle cooperative intelligent fluidized bed granulation coating system and method, and relates to the technical field of pharmaceutical machinery, the system comprises a nozzle unit, and a plurality of micro nozzles arranged in an annular array mode; the air pressure feedback adjusting system is used for dynamically adjusting the atomizing pressure and the spraying angle of each nozzle; the temperature monitoring and control unit comprises an infrared thermal imaging sensor and an artificial intelligence algorithm module and is used for monitoring the surface temperature of particles in the fluidized bed in real time and automatically adjusting the hot air flow and temperature; the aperture gradient of the detachable porous distribution plate is simulated and optimized through computational fluid dynamics; and the control system is used for coordinating the work of each unit. According to the invention, the annular array micro nozzles are adopted to replace a traditional single nozzle, so that uniform coverage of the coating liquid on the particle surface is realized; an infrared thermal imaging sensor and an artificial intelligence algorithm are integrated, real-time and high-precision monitoring and automatic feedback adjustment of the surface temperature of particles in the fluidized bed are achieved, and the quality and stability of products are ensured.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of pharmaceutical machinery, and in particular to an intelligent fluidized bed granulation coating system and method with multiple nozzles in cooperation with atomization. BACKGROUND

[0002] In the field of pharmaceutical granulation coating process, fluidized bed technology is widely used. However, the traditional fluidized bed system has several long-term unresolved pain points. First, uneven coating is a big problem. The traditional single-nozzle fluidized bed coating system is difficult to make the coating liquid evenly cover the surface of the particles, resulting in uneven coating quality, affecting the drug release effect and appearance. Secondly, it is difficult to accurately control the temperature distribution in the fluidized bed. Local overheating areas are prone to cause degradation of heat-sensitive drug ingredients, seriously affecting the quality and efficacy of the final product. In addition, uneven airflow distribution will cause "dead bed" areas in the fluidized bed, and some particles cannot be fully fluidized, resulting in ineffective adhesion of coating liquid in these areas, significantly reducing the coating efficiency and production efficiency; at the same time, there is a lack of effective temperature and thermal monitoring system, which cannot meet the low-temperature granulation needs of heat-sensitive ingredients.

[0003] To solve the above problems, the prior art has made some attempts. For example, the Chinese patent with publication number CN107321276A discloses a product quality controllable hot melt fluidized bed microcapsule preparation system and method, which sprays liquid condensation from the nozzle while coating on the surface of the fluidized powder, realizing low-temperature fluidization spray granulation. However, it still has the problem of uneven coating. The Chinese patent with publication number CN108883385A discloses an electro-spray device for a fluidized bed apparatus, a fluidized bed apparatus and a method, which optimizes the process by using electromagnetic fluid dynamics, but still has the problem of inaccurate temperature control.

[0004] Therefore, there is an urgent need in the art for a new intelligent fluidized bed system that can comprehensively solve the problems of coating uniformity, temperature control accuracy and airflow distribution uniformity, and meet the low-temperature granulation needs of heat-sensitive ingredients. SUMMARY

[0005] The purpose of the present application is to solve the above technical problems and provide an intelligent fluidized bed granulation coating system and method with multiple nozzles in cooperation with atomization, which comprehensively uses multiple nozzles in cooperation with atomization, intelligent temperature control and airflow optimization, significantly improves coating uniformity and efficiency, reduces material loss, and is suitable for low-temperature granulation of heat-sensitive ingredients.

[0006] In order to achieve the above technical purpose and meet the above technical requirements, the technical solution adopted by the present application is as follows: an intelligent fluidized bed granulation coating system with multiple nozzles in cooperation, comprising: a nozzle unit comprising a plurality of micro-nozzles arranged in a ring array; a gas pressure feedback regulation system connected with the micro-nozzles for dynamically adjusting the atomization pressure and spray angle of each nozzle; a temperature monitoring and control unit including an infrared thermal imaging sensor and an artificial intelligence algorithm module for real-time monitoring of the particle surface temperature in the fluidized bed and automatic adjustment of the hot air flow and temperature; an airflow distribution optimization unit including a detachable porous distribution plate with a pore size gradient optimized by computational fluid dynamics simulation; a control system for coordinating the operation of the nozzle unit, gas pressure feedback regulation system, temperature monitoring and control unit, and airflow distribution optimization unit.

[0007] Preferably, the number of micro-nozzles is set to 4-8.

[0008] Preferably, the gas pressure feedback regulation system dynamically controls the atomization pressure of each nozzle within the range of 0.2MPa-0.5MPa and the spray angle within the range of 30°-60°.

[0009] Preferably, the gas pressure feedback regulation system dynamically adjusts the atomization pressure and spray angle of each nozzle according to the coverage of the particle surface coating liquid to achieve uniform coverage of the coating liquid and make the coating thickness deviation less than 3%.

[0010] Preferably, the temperature monitoring accuracy of the infrared thermal imaging sensor is ±0.5℃.

[0011] Preferably, the artificial intelligence algorithm module automatically adjusts the hot air flow within the range of 20m 3 / min-50m 3 / min and the temperature within the range of 30℃-70℃ according to the temperature data.

[0012] Preferably, the system is configured to control the temperature below 40℃ to be suitable for low-temperature granulation of heat-sensitive ingredients.

[0013] Preferably, the pore size gradient of the detachable porous distribution plate is 0.5mm-2mm, and the airflow distribution optimization unit is configured to improve the uniformity of the airflow velocity field by 40% and control the "dead bed" area to less than 5% of the bed area.

[0014] A multi-nozzle coordinated intelligent fluidized bed granulation and coating method using the above system, comprising the following steps: Step S1: dynamically control the atomization pressure and spray angle of the multiple micro-nozzles arranged in a ring array through the gas pressure feedback regulation system; Step S2: real-time monitoring of the particle surface temperature in the fluidized bed through the infrared thermal imaging sensor and automatic adjustment of the hot air flow and temperature using the artificial intelligence algorithm; Step S3: Using a detachable porous distribution plate, the pore size gradient is optimized through computational fluid dynamics simulation to optimize airflow distribution; Step S4: Determine whether the coating solution uniformly covers the particle surface, whether the temperature is controlled within the ideal range, and whether the airflow velocity field is uniform; If the conditions are met, the granulation and coating process is complete. If the conditions are not met, return to step S1 for adjustment.

[0015] Preferably: In step S1, the atomization pressure of each nozzle is controlled within the range of 0.2MPa-0.5MPa, and the spray angle is controlled within the range of 30°-60°; in step S2, the hot air flow rate is controlled within 20m³ / h. 3 / min-50m 3 Within the range of / min, the temperature is in the range of 30℃-70℃, and can be further controlled below 40℃ to be suitable for low-temperature granulation of heat-sensitive components; in step S3, the pore size gradient of the detachable porous distribution plate is 0.5mm-2mm.

[0016] Compared with the traditional structure, the beneficial effects of the present invention are as follows: 1. The present invention has high coating uniformity. It adopts 4-8 micro nozzles distributed in a ring array and uses a pressure feedback adjustment system to dynamically control the atomization pressure and spray angle of each nozzle, so as to achieve uniform coverage of coating liquid on particle surface, solve the problem of uneven coating of traditional single nozzle, and the coating thickness deviation can be less than 3%, and the coating effect is more uniform. 2. This invention offers precise temperature control and high product quality. By integrating an infrared thermal imaging sensor and artificial intelligence algorithms, it achieves real-time, high-precision monitoring and automatic feedback adjustment of the particle surface temperature within the fluidized bed. This effectively prevents drug component degradation caused by localized overheating, ensuring product quality and stability. 3. This invention provides uniform airflow distribution, improving coating efficiency. By optimizing the detachable porous distribution plate with pore size gradient through computational fluid dynamics simulation, the uniformity of the airflow velocity field is improved by 40%, the "dead bed" area is reduced, coating efficiency is increased by 50%, and material loss is reduced by 20%. 4. This system and method can achieve precise low-temperature control below 40℃, meeting the low-temperature granulation and coating requirements of heat-sensitive drug components and expanding the application scope of fluidized bed technology. Detailed Implementation

[0017] The present invention will be further described below.

[0018] Example 1: A multi-nozzle collaborative intelligent fluidized bed granulation and coating system, comprising a nozzle unit, a pressure feedback regulation system, an infrared thermal imaging sensor, an artificial intelligence algorithm module, a detachable porous distribution plate, and a control system.

[0019] The nozzle unit consists of six micro-nozzles arranged in a ring array, evenly distributed above the fluidized bed cavity. A pressure feedback regulation system is connected to these nozzles, dynamically controlling the atomization pressure of each nozzle within a range of 0.3 MPa and the spray angle within a range of 45°. This system can fine-tune the atomization pressure and spray angle of each nozzle based on real-time monitoring of the coating liquid coverage on the particle surface, ensuring uniform coating liquid coverage of the particle surface and a coating thickness deviation of less than 3%.

[0020] The infrared thermal imaging sensor is installed on the side wall of the cavity to monitor the surface temperature of particles in the fluidized bed in real time, with a temperature accuracy of ±0.5℃. Its data is transmitted to an artificial intelligence algorithm module, which automatically adjusts the hot air flow rate to 30m³ based on the temperature data. 3 The speed is 40℃, and the temperature is 40℃. It is suitable for low-temperature granulation of heat-sensitive ingredients.

[0021] The detachable porous distribution plate was optimized to have a pore size gradient of 0.8-1.5 mm through computational fluid dynamics simulation. This design makes the airflow velocity field through the distribution plate more uniform, improving the uniformity of the airflow velocity field by 40% and effectively reducing the "dead bed" area (less than 5% of the total bed area).

[0022] The control system coordinates the operation of all the aforementioned units.

[0023] The control method of this system includes the following steps: Step S1: Start the system and control the atomization pressure of the 6 nozzles to perform coordinated atomization at 0.3MPa and a spray angle of 45°. Through the coordinated atomization of the nozzle array, the uniformity of coating liquid coverage is improved. Step S2: An infrared thermal imaging sensor monitors the particle surface temperature in real time, and an artificial intelligence algorithm automatically adjusts the hot air temperature to 40℃ and the flow rate to 30m³ based on the temperature data. 3 / min, to avoid localized overheating that could lead to component degradation; Step S3: Use a detachable porous distribution plate with a pore size gradient of 0.8-1.5mm to ensure uniform airflow and reduce "dead bed" areas; Step S4: Determine whether the coating solution evenly covers the particle surface, whether the temperature is controlled at 40℃, and whether the airflow velocity field is uniform. If all conditions are met, the granulation and coating process is complete. If any condition is not met, return to step S1 for adjustment.

[0024] Example 2: A multi-nozzle collaborative intelligent fluidized bed granulation and coating system, comprising a nozzle unit, a pressure feedback regulation system, an infrared thermal imaging sensor, an artificial intelligence algorithm module, a detachable porous distribution plate, and a control system.

[0025] The nozzle unit consists of eight micro-nozzles arranged in a ring array. A pressure feedback regulation system is connected to these nozzles, dynamically controlling the atomization pressure of each nozzle within a range of 0.4 MPa and the spray angle within a range of 35°. Based on real-time monitoring of the coating liquid coverage on the particle surface, the system fine-tunes the atomization pressure and spray angle of each nozzle to ensure uniform coating liquid coverage of the particle surface with a coating thickness deviation of less than 3%.

[0026] The infrared thermal imaging sensor is installed on the side wall of the cavity to monitor the surface temperature of particles in the fluidized bed in real time, with a temperature accuracy of ±0.5℃. Its data is transmitted to the artificial intelligence algorithm module, which automatically adjusts the hot air flow rate to 25m³ based on the temperature data. 3 The speed is 35℃, and the temperature is 35℃. It is suitable for low-temperature granulation of heat-sensitive ingredients.

[0027] The detachable porous distribution plate was optimized to have a pore size gradient of 0.6-1.2 mm through computational fluid dynamics simulation. This design makes the airflow velocity field through the distribution plate more uniform, improving the uniformity of the airflow velocity field by 40% and effectively reducing the "dead bed" area (less than 5% of the total bed area).

[0028] The control system coordinates the operation of all the aforementioned units.

[0029] The control method of this system includes the following steps: Step S1: Start the system and control the atomization pressure of the 8 nozzles to perform coordinated atomization at 0.4MPa and 35° spray angle. Through the coordinated atomization of the nozzle array, the uniformity of coating liquid coverage is improved. Step S2: An infrared thermal imaging sensor monitors the particle surface temperature in real time, and an artificial intelligence algorithm automatically adjusts the hot air temperature to 35℃ and the flow rate to 25m³ based on the temperature data. 3 / min, to avoid localized overheating that could lead to component degradation; Step S3: Use a detachable porous distribution plate with a pore size gradient of 0.6-1.2mm to ensure uniform airflow and reduce "dead bed" areas; Step S4: Determine whether the coating solution evenly covers the particle surface, whether the temperature is controlled at 35℃, and whether the airflow velocity field is uniform. If all conditions are met, the granulation and coating process is complete. If any condition is not met, return to step S1 for adjustment.

[0030] The above embodiments of the present invention are merely examples to clearly illustrate the present invention, and are not intended to limit the scope of protection of the present invention. All equivalent technical solutions also fall within the scope of the present invention, and the patent protection scope of the present invention should be defined by the claims.

Claims

1. A multi-nozzle co- intelligent fluidized bed granulation coating system, characterized in that: The system comprises: a nozzle unit comprising a plurality of micro-nozzles arranged in a circular array; a gas pressure feedback regulation system connected to the micro-nozzles for dynamically adjusting the atomization pressure and spray angle of each nozzle; a temperature monitoring and control unit comprising an infrared thermal imaging sensor and an artificial intelligence algorithm module for real-time monitoring of the surface temperature of the particles in the fluidized bed and automatic adjustment of the hot air flow and temperature; a gas flow distribution optimization unit comprising a detachable perforated distribution plate with a pore size gradient optimized by computational fluid dynamics simulation; a control system for coordinating the operation of the nozzle unit, gas pressure feedback regulation system, temperature monitoring and control unit, and gas flow distribution optimization unit.

2. The multi-nozzle co-intelligent fluid bed granulation coating system according to claim 1, characterized in that: The number of micro-nozzles is set to 4-8.

3. The multi-nozzle co-intelligent fluid bed granulation pan coating system as claimed in claim 1, wherein: The gas pressure feedback regulation system dynamically controls the atomization pressure of each nozzle within the range of 0.2-0.5 MPa and the spray angle within the range of 30-60°.

4. The multi-nozzle co-intelligent fluid bed granulation pan coating system as claimed in claim 1, wherein: The gas pressure feedback regulation system dynamically adjusts the atomization pressure and spray angle of each nozzle according to the coverage of the coating liquid on the particle surface to achieve uniform coverage of the coating liquid and a coating thickness deviation of less than 3%.

5. The multi-nozzle co-intelligent fluid bed granulation pan coating system as claimed in claim 1, wherein: The temperature monitoring accuracy of the infrared thermal imaging sensor is ±0.5℃.

6. The multi-nozzle co-intelligent fluid bed granulation pan coating system as claimed in claim 1, wherein: The artificial intelligence algorithm module automatically adjusts the hot air flow in the range of 20m 3 / min-50m 3 / min according to the temperature data, and the temperature is in the range of 30℃-70℃.

7. The multi-nozzle co-intelligent fluid bed granulation pan coating system as claimed in claim 6, wherein: The system is configured to control the temperature below 40℃ to be suitable for low-temperature granulation of heat-sensitive ingredients.

8. The multi-nozzle co-intelligent fluid bed granulation pan coating system as claimed in claim 1, wherein: The pore size gradient of the detachable perforated distribution plate is 0.5-2 mm, and the gas flow distribution optimization unit is configured to improve the uniformity of the gas flow velocity field by 40% and control the "dead bed" area to less than 5% of the bed area.

9. A multi-nozzle synergistic intelligent fluid bed granulation coating process using the process as claimed in any one of claims 1-8, characterized by: The method comprises the following steps: Step S1: dynamically control the atomization pressure and spray angle of the plurality of micro-nozzles arranged in a circular array through the gas pressure feedback regulation system; Step S2: real-time monitoring of the surface temperature of the particles in the fluidized bed through the infrared thermal imaging sensor and automatic adjustment of the hot air flow and temperature using the artificial intelligence algorithm; Step S3: adopt a detachable perforated distribution plate and optimize the pore size gradient through computational fluid dynamics simulation to optimize the gas flow distribution; Step S4: determine whether the coating liquid uniformly covers the particle surface, whether the temperature is controlled within the ideal range, and whether the gas flow velocity field is uniform; If the conditions are met, the granulation and coating are completed; If the conditions are not met, return to step S1 for adjustment.

10. The multi-nozzle coordinated intelligent fluidized bed granulation and coating method according to claim 9, characterized in that: In step S1, the atomization pressure of each nozzle is controlled within the range of 0.2-0.5 MPa, and the spray angle is controlled within the range of 30-60°; In step S2, the hot air flow is controlled in the range of 20 m 3 / min-50 m 3 / min, and the temperature is controlled in the range of 30°C-70°C, and further controlled below 40°C, to suit the low temperature granulation of heat-sensitive ingredients; In step S3, the pore size gradient of the detachable perforated distribution plate is 0.5-2 mm.