Granulating device and granulating method

Abstract

The invention relates to a granulating device (1), comprising a granulating system (2) which is equipped with a process container (3) having a container wall (5) which surrounds a process chamber (4). A granulation process can be carried out in the process chamber (4) for producing pellets (11) consisting of a plurality of pellets (12), the operating state of which can be influenced by variable operating parameters. The image acquisition unit (42) is arranged in the region of the granulation plant (2) such that it can perform image acquisition of the process chamber (4) during the granulation process and in turn also perform online image acquisition of pellets (11) undergoing the granulation process in the process chamber (4). In this way, the granulation process can be reliably monitored. The invention further relates to a granulation method using in-line image acquisition of the process chamber (4), which granulation method is carried out in particular using the granulation device (1).

Description

Technical Field

[0001] This invention relates to a granulation apparatus comprising: a granulation facility having a process container having a container wall surrounding a process chamber, wherein a granulation process suitable for producing granules composed of a large number of granules can be performed within the process chamber, the operating state of the granulation process being affected by operating parameters; and an electronically controllable image acquisition unit for acquiring two-dimensional images of the granules produced by the granulation process, these images being analyzed in an electronic control mechanism designed to set variable operating parameters for the granulation process.

[0002] The present invention also relates to a granulation method, particularly executable by a granulation apparatus of the type described above, for producing granules composed of a large number of granular particles, wherein a granulation process accompanying particle growth is carried out in a process chamber defined by the container wall of a process vessel, the granulation process being monitored using an electrically controlled image acquisition unit, which acquires two-dimensional images of the granules using the image acquisition unit, and then evaluates the image acquisition by means of an electronic control mechanism, and the evaluation is taken into consideration for setting variable operating parameters that affect the operating state of the granulation process. Background Technology

[0003] A granulation apparatus constructed and operable in the manner described above is known from DE 100 61 085 A1. Here, the granulation apparatus includes a granulation section containing a granulation roller, downstream of which is a discharge chute with a hopper. Granules produced in the granulation section are continuously fed vertically to the discharge chute on the input side. The granules obtained in this manner can be removed at a sampling port in the discharge chute and supplied to a field unit equipped with a color camera. The granules fall downwards within the object plane of the color camera, wherein a sequence of images of the falling granules is captured during the fall. During the acquisition of the image sequence, the particle size and particle size distribution are determined by means of the color camera based on the particle projection area. In a downstream computing unit, the captured image sequence is analyzed and digitally processed so that it can be displayed on an output mechanism, for example, designed as a monitor. Process-specific parameters are also determined in the computing unit, which serve as input variables for a device controller with a fuzzy logic module. After comparison with target values, an output signal is generated to influence the operating parameters of the granulation process according to the desired product quality. Image sequences can be captured not only in the field unit but also directly from the granules falling into the feed chute from the granulation section. This known apparatus can be used to produce, for example, fertilizers and pharmaceutical products.

[0004] WO 2019 / 091507 A1 describes a method and apparatus for producing particulate solid particles, wherein the produced particles are detected using an optical inspection system, and at least one characteristic parameter of the produced particles is determined from the optical inspection data of the produced particles. Based on the determined characteristic parameter, at least one parameter in subsequent particle production processes can then be automatically influenced. The optical inspection of the particles is performed after they leave a process container in which a granulation process has already taken place. This process container, for example, is equipped with a granulation disc, in which the supplied initial material agglomerates due to the rotational movement of the granulation disc. Control data is generated by means of, for example, an electronic control mechanism implemented by a computer, which is considered for optimizing subsequent granulation processes, such as controlling a valve assembly that can influence the supply of initial material in the granulation process.

[0005] Leaving aside the aforementioned prior art, the applicant has internal knowledge of granulation equipment, in which a granulation process is used to produce microgranules. During the granulation process, operators periodically use a sampler to extract samples from the production equipment and observe the results outside the equipment using a microscope or camera. A small number of extracted particles are manually measured and analyzed using system software when necessary. Subsequent process control depends on these observations. Because the growth process of the generated granules is very rapid, samples often cannot be extracted and analyzed at a sufficient rate, resulting in uncontrolled particle growth and failure to achieve the desired product performance. Another limitation of this process-integrated inspection method is that it relies on experienced operators and the number of analyzable particles in each sample is relatively small. Summary of the Invention

[0006] The purpose of this invention is to adopt measures that enable rapid analysis of the granulation process along with the process, thereby reliably and repeatedly producing high-quality granules.

[0007] In the granulation apparatus incorporating the features described at the outset, the objective is achieved by arranging an image acquisition unit within the granulation facility area, enabling the image acquisition unit to acquire images of the process chamber during the granulation process, thereby achieving online image acquisition of the granules undergoing the granulation process within the process chamber.

[0008] Furthermore, this objective is also achieved through a granulation method of the type described at the beginning, wherein during the granulation process, images of the granules growing in the process chamber are acquired as online image acquisition.

[0009] According to the present invention, there is an advantageous feasibility where the granulation process performed in the granulation apparatus is monitored online, i.e., directly within the process chamber during granulation by observing the granules undergoing size growth. A granulation method can be performed in which images of the growing granules within the process chamber are acquired as online image acquisition during the granulation process. In this way, a rapid response to the current process flow can be achieved, for example, a response to rapid particle growth. Unlike intermittent sampling, since this assessment can be performed while observing a large number of granules, the obtained analytical results are significantly more accurate and representative. Therefore, excellent and stable product quality and extremely low scrap rates can be achieved. This analysis is based on optical data provided by an image acquisition unit arranged within the granulation process area, enabling two-dimensional (2D) image acquisition from inside the process chamber during the granulation process, thereby acquiring two-dimensional (2D) images of the granules currently undergoing granulation within the process chamber. During these online image acquisitions, the granulation process can proceed undisturbed. The image acquisition unit can be placed, for example, inside or outside the process chamber, and can acquire images of the interior of the process chamber through the structure of the process container. When performing this method, the granules currently undergoing granulation in the process chamber can be directly photographed, and after subsequent analysis of the acquired images, an influence can be exerted on the subsequent granulation process by modifying the variable operating parameters of the current granulation process based on the acquired images. Because images can be acquired in real time, the measures of the present invention have also shown particular advantage for monitoring and controlling granulation processes where particles grow rapidly, as online optical evaluation can influence the method with extremely short reaction times. With the aid of online image acquisition (which is particularly used to create image sequences consisting of multiple images acquired directly and sequentially), the granulation process can be monitored in various ways based on optically detectable product parameters (e.g., particle size, particle size distribution, roundness, or other morphological characteristics). Preferably, the granulation apparatus is designed to enable image acquisition of granules in a regular, particularly freely selectable, and preferably adjustable-to-production-speed image sequence. The types of variable operating parameters responsible for and affecting the operating status of the granulation process depend on the construction and configuration of the granulation facility, and may involve, for example, temperature, volumetric flow rate, and / or operating time.

[0010] Although the plural form of operating parameters has been used above and below, variable operating parameters in simple device constructions or process flows may also include only a single variable operating parameter. Referring to a variable operating parameter should be understood as referring to one or more variable operating parameters.

[0011] Advantageous embodiments of the invention are described in the dependent claims.

[0012] The granulation apparatus used in this invention can, in principle, be based on any operating principle. Advantageously, the granulation apparatus is designed as a fluidized bed granulation apparatus, which induces fluidization of the granules during the granulation process by means of a flowing process gas. Particularly suitable are fluidized bed granulators, especially for spray granulation, spray agglomeration, spray coating, or spray encapsulation. This process facilitates the rotation of the granules within the process vessel, forming a so-called fluidized bed. For specific requirements, splash bed technology can be employed.

[0013] Designing the fluidized bed generator as a rotor-fluidized bed granulator is considered particularly advantageous. This generator is equipped with a motor-driven rotor that suitably has rotor plates. Granulation facilities using this configuration can produce granules with extremely high quality roundness and surface finish. The rotating rotor plates convey the granules outward into the process gas stream, where they are then carried away by the gas, forming a fluidized bed, particularly annular one.

[0014] The aforementioned rotor-fluidized bed generator is one possible implementation of a granulation facility (generally referred to as a rotor-granulator) that can be used within the scope of this invention. In another embodiment of the rotor-granulator (which is also advantageous within the scope of this invention), the process gas (especially air) flowing through the process vessel and through the rotor is primarily or solely used as a barrier gas, while the actual granulation process is achieved by the granules moving through the process chamber in a particularly annular flow of granules and being continuously mixed via a rotating rotor, combined with paddle-like structures arranged on the rotor and / or process vessel. Highly rounded granules are produced as the granules roll on the surfaces of the process vessel and rotor (including the paddle-like structures).

[0015] Granulation facilities can be designed, for example, for so-called high-shear granulation. High-shear granulation is a forming method for granulation in which a binder liquid is supplied to powdered particles within a closed process vessel containing a mixing tool and a shredder. The mixing tool suitably includes a motorized rotor, hence the granulation facility can also be called a rotor granulator. Dense granules are formed through the resulting liquid and solid bridges.

[0016] In a preferred design of the granulation apparatus, the residence time of the granules during the continuous granulation process (hereinafter also referred to as processing time) is set as a variable operating parameter. In a granulation apparatus designed for intermittent operation, the processing time can be set, for example, by starting and stopping the granulation process. In continuous granulation, the processing time is specifically obtained from the time difference between the introduction of the initial material and the entry or exit of the granules into the continuous granulation process. When performing this method, the processing time can be set, for example, by an electronic control mechanism for evaluating two-dimensional images acquired by an image acquisition unit.

[0017] The process chamber of the granulation facility's process vessel is suitably connected to a process gas inlet designed for the input of appropriately temperature-controlled process gas, and also to a process gas outlet for the discharge of the input process gas. The process gas is, for example, heated air or heated inert gas. The process gas, for example, dries the material located within the process chamber, thereby achieving granulation, for example, by spray granulation or spray agglomeration. Additionally or alternatively, the process gas, particularly in rotary granulators, can be used as a barrier gas to prevent granule particles from falling downwards between the rotating rotor and the vessel wall of the process vessel. Advantageously, the volumetric flow rate and / or temperature of the process gas are provided as variable operating parameters, which can be changed by an electronic control mechanism to influence the operating status of the granulation process, particularly based on the evaluation of acquired images.

[0018] To achieve spray granulation, the granulation facility is preferably equipped with a nozzle assembly that sprays the granulating liquid into the process chamber of the process vessel. When performing the method according to the invention, a liquid containing solids, such as a solution, suspension, or melt, is sprayed into the process chamber in this manner. There, the liquid components evaporate due to a high degree of heat exchange with the process gas, and the remaining solids form small particles that act as carrier cores. These carrier cores are wetted by another liquid, thereby forming a solid coating layer around the carrier cores upon re-evaporation. As this process is repeated continuously, the granules grow layer by layer. Alternatively, in spray agglomeration, extremely small particles existing in powder form move in a fluidized bed generated by the process gas and are sprayed with a binder liquid from the nozzle assembly. Here, due to the formation of liquid bridges, the particles combine to form agglomerated granules, wherein the spray process continues until the desired size of the granules existing as agglomerates is achieved.

[0019] When a nozzle assembly is present, the volumetric flow rate of the granulating liquid supplied to the process chamber and / or the spray duration and / or droplet size are considered as variable operating parameters of the granulation process.

[0020] The granulation facility is preferably equipped with a feeding mechanism that introduces the carrier core, particularly in powder form, upon which the granulation structure is based, into the process chamber. In this method, the subsequently injected granulation liquid serves only as a transport component for introducing the solid material to be coated layer by layer. In this case, a variable operating parameter of the granulation process can be the number of carrier cores available to be supplied to the process chamber.

[0021] If the granulation facility has a rotor that can be rotated by a motor, the variable operating parameter of the granulation process can be the rotational speed of the rotor, which can be set in particular by the corresponding control of the associated electric drive motor.

[0022] Depending on the construction of the granulation apparatus, image acquisition of the granules can be performed by an image acquisition unit placed directly inside the process chamber or by an image acquisition unit arranged outside the process chamber. For safety reasons, particularly explosion-proof considerations, it is generally preferred that the image acquisition unit be placed in the external area of ​​the process container. In this case, the container wall of the process container suitably has at least one transparent section, in which the image acquisition unit is arranged outside the process chamber, allowing it to acquire images of the process chamber through the transparent section, and thus acquire images of the granules located therein. When performing the granulation method according to the invention based on this, online image acquisition of the granules located in the process chamber is performed from outside the process chamber through the transparent section of the container wall of the process container.

[0023] The transparent wall segment is specifically a limited area of ​​the container wall that is surrounded by an opaque wall segment of the container wall, thereby defining a transparent observation window. This observation window is preferably made of transparent glass or plastic.

[0024] Alternatively, the process container can be constructed such that the container walls are at least primarily (preferably entirely) made of a transparent material, such as a high-quality transparent plastic, wherein the transparent wall segments used for image acquisition are portions of a large area of ​​the transparent container wall.

[0025] The image acquisition unit, located outside the process chamber and thus externally placed, can be mounted on a separate support structure, independent of the process container, but is preferably directly fixed to the outside of the process container. Preferably, the process container has a fixing interface (referred to as the container-fixing interface) on its outer wall, which matches the structure of the image acquisition unit, and the image acquisition unit is fixed to this interface in the position used for performing the method. Preferably, the container-fixing interface is designed for screwing the image acquisition unit in place, so that the image acquisition unit can be easily and quickly removed from the process container for maintenance or other reasons.

[0026] For ease of detachable mounting onto the process vessel, the image acquisition unit is suitably equipped with a fixed interface, which, for easy distinction, is referred to as the image acquisition unit-fixed interface. This image acquisition unit-fixed interface is functionally identical to the aforementioned optional vessel-fixed interface.

[0027] The image acquisition unit is suitably equipped with an electromechanical connection mechanism through which it can be electrically connected to an electronic control unit that sets one or more variable operating parameters for the granulation process. This electromechanical connection mechanism suitably includes a plug connection mechanism for at least one cable, or it may itself be at least one output cable.

[0028] An internet connection is established through an electromechanical connection mechanism, particularly with an electronic control mechanism, which enables data exchange between the two components and is also suitable for power supply through the electromechanical connection mechanism at the required operating voltage.

[0029] Electronic control mechanisms are suitable components of granulation equipment.

[0030] The image acquisition unit for the granulation method is preferably equipped with an optoelectronic component having an image sensor and a lens positioned in front of the image sensor and facing the image to be acquired. The image sensor is suitably a component of a sensor unit integrated into the optoelectronic component, which, in addition to the image sensor, has other electronic and / or mechanical components. The sensor unit and the lens together constitute a camera, particularly a color camera, but it can also be designed as a monochrome camera.

[0031] The preferred lens is a telecentric lens, which appropriately has a fixed focal length. This offers the advantage that when focusing on an image area, the grain size is precisely determined, and unlike wide-angle lenses, the distinction between small grains in the foreground and large grains in the background is clearly visible. Compared to telecentric lenses with variable focal lengths, which are also usable in principle (requiring adjustment of the focal plane by changing the lens), fixed-focal-length telecentric lenses allow for significantly simplified adjustments and evaluations, eliminating the need for complex conversions and calibrations. Each captured pixel always corresponds precisely to a length unit dependent on the lens design, thus eliminating the need for particularly complex conversions for image analysis. Telecentric lenses specifically employ a double telecentric design.

[0032] A telecentric lens with a suitable fixed focal length achieves a relatively small depth of field, for example, within a range of only 1.1 mm. Therefore, precise positioning of the focal plane, defined by the optical elements, is required to determine the image acquisition plane with optimal image sharpness. To allow for the highest possible flexibility in adjustment, it is advantageous for the image acquisition unit to have an electrically actuated linear module with photoelectric components. This linear module allows for stepless linear movement of the photoelectric components to change and adjust the position of the focal plane (also known as the focusing plane). A fixed distance is suitably maintained between the lens and the image sensor, which remains constant even when the position of the photoelectric components changes. Therefore, even when the focal plane is changed, calibration is not required; simply position the photoelectric components appropriately so that the particles to be acquired are within the working area or the focal plane of the lens.

[0033] Instead of electrically actuated linear modules, the image acquisition unit for positioning optoelectronic components can alternatively include other types of positioning mechanisms, such as manually actuated mechanisms with clamping screws, for detachable fixing at any desired location.

[0034] To record clear images, it is advantageous for the image acquisition unit to have an illumination mechanism that illuminates the area of ​​the image to be acquired, typically at least the focal plane of the photoelectric component. This illumination mechanism is preferably designed using LED technology. In performing this method, the illumination mechanism can operate in a pulsed mode matching the image acquisition frequency, but it can also operate in a continuous mode. The latter is technically easier to implement because the recorded image does not require adjustment of the exposure time based on the flash's appearance. Furthermore, continuous illumination offers advantages in terms of explosion protection as it avoids ignition sparks.

[0035] As the illumination medium, the illumination mechanism preferably comprises a ring lamp arranged coaxially with the optical axis of the photoelectric component. In this way, particles moving on the focal plane can be captured without producing interfering shadows, thus enabling accurate measurement. The illumination of the focal plane is very uniform.

[0036] The granulation apparatus suitably includes the aforementioned electronic control mechanism, which evaluates two-dimensional image acquisition of the granules within the process chamber during the granulation process and sets variable operating parameters of the granulation process or apparatus based on the evaluation results to influence the operating status and, consequently, the process conditions as needed. Specifically, image data from the acquired images can be transmitted from the electrically driven image acquisition unit to the electronic control mechanism using the aforementioned electromechanical connection mechanism.

[0037] Preferably, bidirectional signal transmission is possible between the image acquisition unit and the electronic control mechanism. This can be used not only for image evaluation but also for the electrical control of the image acquisition unit, including transmitting electronic image acquisition commands to trigger the desired image acquisition. This is suitably done wiredly via appropriate electrical communication lines, but can also be done wirelessly, particularly via radio transmission.

[0038] The electronic control mechanism suitably includes an electronic data processing mechanism designed to perform image processing on images acquired by the image acquisition unit, and to perform such image processing when executing the method according to the invention. Specifically, the electronic data processing mechanism is capable of calculating granule-related result values ​​based on the obtained image data; for simplicity, these result values ​​are also referred to hereinafter as result values. These result values ​​are, in particular, one or more characteristic parameters, which are, for example, from the group consisting of: the average particle diameter of the granules, the size distribution of the granules, and the average particle diameter. Considering the image sequence, a particle growth curve can be generated based on the size distribution, from which the time progression of particle growth can be determined. Overall, the granule-related result values ​​reflect the current actual state of the granule quality during the granulation process.

[0039] The electronic data processing unit can suitably perform image processing such that the calculation of particle-related result values ​​is based, at least substantially, solely on particle particles located on the focal plane of the image processing unit. This is particularly important when using telecentric lenses, ensuring that the considered particle particles have the same reading or measurement scale, thus preventing significant errors in the calculated result values. For better distinction, particle particles located on the focal plane are referred to as reference-particles, and only these identified as reference-particles are considered when calculating particle-related result values. Particle size is preferably considered here, where particle size, particularly particle diameter, can be inferred based on electronically measured particle circumference.

[0040] The electronic control unit is suitably equipped with an electronic operating state setting mechanism that communicates with an electronic data processing unit and is configured to set variable operating parameters affecting the operating state of the granulation process based on previously determined granulation-related result values. To this end, the operating state setting mechanism can output signals (referred to as operating signals) corresponding to the desired operating parameters to the device components of the granulation unit responsible for the relevant operating parameters. Operating signals—depending on the configuration—may be output, for example, to a liquid pump injecting the granulation liquid, a conveying unit of the carrier core feeding mechanism, a drive motor of a rotor fluidized bed granulator, and / or a blower supplying process gas, and when the method according to the invention is performed, these operating signals are transmitted via the operating state setting mechanism to, for example, one or more of the aforementioned device components.

[0041] The electronic operating status setting mechanism can be an independent module of the electronic control mechanism or an integrated component of the electronic data processing mechanism.

[0042] The electronic control mechanism is preferably designed to perform control, particularly in a closed-loop control circuit, for generating a setpoint signal. To this end, the electronic control mechanism is equipped with a control unit that compares a particle-related result value calculated based on two-dimensional image acquisition with a pre-stored target value, wherein, as a result of the comparison, a setpoint signal is generated for an electronic operating state setting mechanism. Suitably, in the control unit, the particle-related result value is used as a controlled variable, which is compared with a pre-stored target value stored as a reference variable. The operating state setting mechanism is able to interpret the obtained setpoint signal and, based on this, output an operating signal as a manipulated variable to the device components.

[0043] Suitablely, the electronic control mechanism is equipped with an input mechanism, through which target values, in particular, can be input into the electronic data processing mechanism for internal storage. This input mechanism may include, for example, an interface to a keyboard and / or electronic input devices.

[0044] Furthermore, it is advantageous that the electronic control unit has an electronic output mechanism, through which, in particular, the result values ​​related to the granules calculated by the electronic data processing unit can be output (and output when performing the method according to the invention). This output mechanism can also be designed to output other process-related information, such as the current operating status of the granulation apparatus, such as information about the temperature of the process gas or the flow rate of the injected granulation liquid. If the output mechanism includes a display mechanism for visualizing the information to be output, particularly effective monitoring can be achieved. Such a display mechanism can, for example, be formed by a monitor capable of displaying the electronically provided information in alphanumeric form and / or in the form of curve sets or graphs. For example, the average size, average size distribution, and / or morphology of the captured granules can be displayed and / or selected for display in the form of continuous curve sets, with freely definable subdivisions, over the course of the process time.

[0045] To ensure smooth and precise operation of the pelletizing apparatus, it is preferable that the electronic control mechanism, a component of the pelletizing apparatus, is appropriately equipped with artificial intelligence (AI), hereinafter referred to simply as "AI". For particularly efficient image processing, it is preferable to use an AI with a convolutional neural network ("Convolutional Neuronal Network"). The AI ​​is able to interpret the captured images, which consist of two-dimensional images, from the image acquisition unit and identify the aforementioned reference pellet particles for calculating the resulting values ​​related to the pellets. High-precision particle recognition can be achieved by training the AI. This training is particularly accomplished manually, i.e., by providing the AI ​​with captured images, in which the reference pellet particles are pre-labeled manually, using the aforementioned input mechanism.

[0046] Artificial intelligence (AI) is suitably also equipped with data processing components, learning algorithms, decision-making components, output components, and interaction components. The data processing component is responsible for processing the data needed to train the AI, which is, for example, manually defined as reference-granular particles in the aforementioned manner. The learning algorithm is responsible for training the AI ​​and includes, for example, machine learning algorithms such as decision trees or artificial neural networks, particularly at least one convolutional neural network. The decision-making component is used for the AI's decision-making process and, to some extent, executes the control process, wherein the decision-making component analyzes available data—particularly granularity-related outcome values ​​and desired target values—and makes targeted decisions. The decision-making component includes, for example, decision rules or heuristic methods. The output component is used to output results or other information in the aforementioned manner, such as generating charts, graphs, or tables, or may simply output text. They can be used, for example, to control output mechanisms. The interaction component is the component that allows the AI ​​to interact with its environment and is designed, for example, as an electrical interface through which setting signals for the operating status setting mechanism are output.

[0047] The granulation method according to the invention can be performed using any granulation apparatus suitable for the method, but it is preferred to use the granulation apparatus according to the invention.

[0048] When performing the granulation method according to the invention, it is appropriate to acquire online images of the granules located in the process chamber from outside the process chamber through a transparent section of the container wall of the process vessel. In this way, the process chamber can be used for the granulation process without being adversely affected by process monitoring, and the image acquisition unit does not come into contact with the granules in production.

[0049] Suitablely, during the execution of the granulation method, an electronic control mechanism is used to perform image processing on images acquired by an image acquisition unit. Through image processing, result values ​​related to the granules are calculated, such as, in particular, the average particle diameter and / or size distribution and / or the average particle diameter of the granules. Based on the result values ​​specific to the granules, setting signals are generated to specify variable operating parameters that affect the operating state of the granulation process.

[0050] Advantageously, during the granulation process, the setpoint signal is generated via control based on a comparison between the resulting value associated with the granules and a specified target value. This is preferably executed within a closed-loop control circuit. This control is preferably performed using a suitable electronic control mechanism.

[0051] Preferably, during the granulation method, image processing is performed as follows: to calculate the result values ​​related to the granules, granules located on the focal plane of the image acquisition unit (42) are identified from the visible granules in the acquired image as reference granules. Only these identified reference granules are used to calculate the result values ​​related to the granules, and for this purpose, electronic measurements are preferably performed on their particle size, particularly their perimeter. Image processing is preferably performed using an electronic data processing mechanism.

[0052] As described above, the granulation method is preferably performed using a granulation apparatus. Specifically, this is a granulation method for producing granules composed of a large number of granular particles, wherein a granulation process accompanying particle growth is carried out in a process chamber defined by the container walls of a process vessel. This granulation process is monitored using an electronically controlled image acquisition unit, which performs two-dimensional image acquisition of the granules. The image acquisition is then evaluated by an electronic control mechanism, and the evaluation is considered for setting variable operating parameters that affect the operating state of the granulation process. During the granulation process, image acquisition of the granules undergoing particle growth within the process chamber is performed as online image acquisition. The granulation method is executed using a granulation apparatus. The granulation apparatus has a granulation facility with a process container having a container wall surrounding a process chamber, wherein a granulation process is performed in the process chamber to produce granules composed of a large number of granular particles. The operating state of the granulation process is affected by operating parameters. The granulation apparatus also has an electrically controlled image acquisition unit. The two-dimensional images of the granules acquired by the image acquisition unit are evaluated in the electronic control mechanism of the granulation apparatus, which is suitably also part of the granulation apparatus. The image acquisition unit is arranged in the area of ​​the granulation facility so that it can acquire images of the process chamber during the granulation process, thereby performing online image acquisition of the granules undergoing the granulation process in the process chamber. Attached Figure Description

[0053] The invention will now be described in more detail with the aid of the accompanying drawings. In the drawings:

[0054] Figure 1 A preferred embodiment of the granulation apparatus according to the present invention is illustrated in a schematic diagram, which is in a state of performing a granulation process when executing a preferred granulation method according to the present invention, wherein the granules located in the process container are shown in a partially enlarged view by a dashed box.

[0055] Figure 2 It shows Figure 1 A magnified view of the local X portion of the dashed box in the image, where, according to Figure 4 The longitudinal sectional view taken along section line II-II shows a preferred embodiment of the image acquisition unit, which is located in its usage position, mounted outside the process container.

[0056] Figure 3 It shows Figure 2 A top view of the layout, which is based on Figure 2 Arrow III indicates the viewing direction. The housing of the image acquisition unit is shown only in dashed lines, and the housing surrounds the relevant components of the image acquisition unit.

[0057] Figure 4 This is an axial front view of the image acquisition unit, which is based on... Figure 2Arrow IV indicates the direction of observation;

[0058] Figure 5 The view relating to the granulation method includes an image portion (b) showing a graph reproduced by the output mechanism, which is a histogram plotting the relationship between the number of granules “A” and the particle diameter “D”, while an image portion (a) shows an image of the granules taken by the image acquisition unit, based on which the graph according to the image portion (b) is generated. Detailed Implementation

[0059] Depend on Figure 1 As can be seen schematically, the granulation apparatus 1, which is described in detail below, has a preferred construction and can be used to perform the granulation process. The granulation apparatus 1 can operate using the granulation method, which will also be described in detail below, to perform the granulation process.

[0060] The granulation apparatus 1 has a granulation facility 2, which has a process container 3, for example, in the shape of a box or barrel, having a container wall 5 that surrounds an internal space called a process chamber 4.

[0061] The process container 3 has a bottom surface 6 facing vertically downwards and a top surface 7 facing vertically upwards in opposite directions. The height direction 8a of the process container 3, defined by the axial direction of the vertical axis 8, is indicated by a dashed line. In the usual position of use of the process container 3, the vertical axis 8 extends vertically.

[0062] The exemplary granulation facility 2 is a fluidized bed granulation facility that transforms the granules 11 currently undergoing the granulation process into a flowable fluid state. Preferably, the granulation facility 2 is a fluidized bed granulator 2a, wherein the granules 11 located in the process chamber 4 are lifted and vortexed during the granulation process by means of process gas supplied according to flow arrow 14, thereby creating a fluidized bed 15 within the process chamber 4. The fluidized bed state can be maintained as long as process gas is input into the process chamber 4.

[0063] Within the fluidized bed 15, the various granular particles 12 of different sizes in the granular material 11 are intensely swirled together, much like a fluid.

[0064] The granulation device 1 can be used to perform a granulation method, which produces granules 11 consisting of a large number of granular particles 12. The material composition of the granular particles 12 depends on the intended use, for example, in the fertilizer field, and especially in the pharmaceutical field. The produced granules 11 are used, for example, to produce fertilizer microparticles or medical tablets.

[0065] In particular, an extraction device 16 is arranged in the area of ​​the bottom surface 6 of the container at the process container 3—which has an extraction port 16a suitable for opening as needed, allowing the extraction of the generated granules 11 for subsequent use. For example, a tableting machine can be connected to the extraction device 16.

[0066] The granulation facility 2 includes a process gas inlet 17 disposed on the process vessel 3, through which the aforementioned process gas can be introduced into the process chamber 4, specifically from below, according to flow arrow 14. The process gas can be, for example, an inert gas, preferably air. An electrically driven blower 18 located upstream of the process gas inlet 17 supplies process gas to the process gas inlet 17 and, consequently, to the process chamber 4, at the required volumetric flow rate and gas pressure.

[0067] The process gas supplied for the granulation process is appropriately temperature-controlled, particularly heated to a suitable temperature. In this way, the process gas can supply the heat energy that may be needed for the granulation process to the process chamber 4. For example, the process gas inlet 17 is equipped with a heat source 21, such as a gas heater designed as a heat exchanger. However, the heat source 21 for heating the process gas can also be installed in other locations, particularly upstream of the blower 18.

[0068] Furthermore, particularly in the region of the top surface 7 of the container, the process gas outlet 22 is connected to the process chamber 4, and this process gas outlet is used to discharge the process gas supplied through the process gas inlet 17. When flowing through the process gas chamber 4, the process gas discharges the heat required for the particulate technology process to the pellets 11 or its raw materials.

[0069] The granulation facility 2 is preferably a rotor granulator 2b, which is applicable to the illustrated embodiment. In this case, according to the illustrated embodiment, the granulation facility 2 has a rotor 23a disposed within the process chamber 4, which is mechanistically rotatable about a rotation axis 20 extending in the height direction 8a, and has a rotor plate 23. To generate the rotational motion of the rotor 23a, there is an electrically actuated drive motor 24, which is mounted outside the process container 3, particularly in the region of the container bottom surface 6. The rotor plate 23 extends along a plane perpendicular to the height axis 8, and is therefore, for example, horizontally oriented. The rotor plate is located within the lower chamber region 4a of the process chamber 4, which corresponds to the container bottom surface 6.

[0070] The container wall 5 has a sidewall 25, for example, a hollow cylindrical design, which extends around the vertical axis 8 and completely surrounds the process chamber 4 on the side. An annular gap 26 (shown enlarged in the figure) is formed between the outer edge of the rotor plate 23 of the rotor 23a and the sidewall 25, through which process gas introduced below the rotor plate 23 via the process gas inlet 17 located there can flow upward through the annular gap.

[0071] For example, the rotor granulator 2b is a fluidized bed granulator 2a constructed as a rotor fluidized bed granulator, wherein the process gas flowing upward through the annular gap 26 interacts with the granular particles 12 in the upper space region 4b of the process chamber 4 located above the rotor plate 23 to generate a fluidized bed 15.

[0072] According to one embodiment (not shown) of the fluidized bed granulator 2a that can be used in the present invention, the rotor 23a is omitted and replaced by a fixed sieve structure, through which the process gas interacting with the granules 12 located above the sieve structure passes from below.

[0073] In another advantageous embodiment of the rotor granulator 2b, the process gas flowing through the process chamber 4 and past the rotor plate 23 according to the flow arrow 14 is used as a barrier gas, which, in particular, prevents the granule particles 12 from passing through the annular gap 25 and falling into the area below the rotor plate 23 in an air curtain manner. Air is used as the process gas in particular. Actual granulation is caused by the rotating rotor 23a, combined with a paddle-shaped structure 9 fixedly disposed on the top of the rotor plate 23 and / or inside the container wall 5 of the process container 3. Figure 1 (As shown by the dashed line in the middle), the granular particles 12 move continuously and mixedly through the process chamber 4 in the form of a particularly annular particle flow. In particular, the granular particles 12 with high roundness are produced when the granular material 11 rolls on the surfaces of the process container 3 and the rotor 23a (including the paddle structure 9).

[0074] The granulation apparatus 1 is designed, for example, to perform a granulation process called spray granulation. Here, granulation liquid supplied in the storage tank 27 of the granulation apparatus 1 is sprayed into the process chamber 4 via a nozzle assembly 28 located within the process chamber 4, as indicated by the dotted line 31. The nozzle assembly 28 is connected to the storage tank 27 via a motor-driven liquid pump 32 of the granulation apparatus 1. During operation of the liquid pump 32, the granulation liquid is drawn from the storage tank 27 and sprayed into the process chamber 4 in a fine distribution, particularly by mixing with air to produce a fine spray.

[0075] Spray granulation can be performed using granulation device 1, where granules 11 are generated solely from the sprayed granulation liquid. Here, a granulation liquid containing solids (e.g., a suspension) is sprayed into process chamber 4, where the aqueous component evaporates, and the remaining solids serve as a carrier core. The carrier core is then wetted by subsequently supplied granulation liquid, and after further evaporation, a solid coating shell is formed around the respective carrier core by the solids. In this continuously repeated granulation process, granular particles 12 with an onion-like layered structure are generated.

[0076] Preferably, the granulation apparatus 1 provides the feasibility of introducing a predetermined amount of suitable carrier cores into the process chamber 4 at the start of the granulation process. At this time, the supplied granulation liquid is not used for core formation but only for layered particle growth. For example, the granulation apparatus 1 is equipped with a suitable feeding mechanism 33 by means of which the carrier cores can be fed into the process chamber 4. The feeding mechanism 33 includes, for example, a motor-driven conveying unit 34 (e.g., designed as a screw conveyor) and a carrier core reservoir 35 connected to the conveying unit 34, which is filled with a sufficient amount of carrier cores during the granulation process.

[0077] The granulation apparatus 1 can also be suitably used for granulation processes that produce granules via spray agglomeration. In this granulation process, extremely small powdery particles move in a fluidized bed via process gas and are sprayed with a granulation liquid, which serves as a binder, from the nozzle assembly 28. In this case, a large number of particles always agglomerate, forming liquid bridges, wherein the spraying process continues until the agglomerates have reached the desired size for the granular particles. The powdery particles can be fed in by means of the feeding mechanism 33.

[0078] To obtain pellets 11 with the desired morphology (especially the desired particle size), the operating state of the ongoing granulation process can be influenced by one or more variable operating parameters. To enable this influence, the granulation unit 1 is equipped with... Figure 1 The electronic control mechanism 36 is shown by the dashed line.

[0079] The electronic control mechanism 36 is electrically connected to the device component 38 of the granulation device 1 via the control line 37 shown by the dashed line. The operating parameters of the device component are variable, and for ease of distinction, it is also referred to as the influenceable device component 38.

[0080] Electrical operating signals can be supplied to the affected device components 38 via control line 37, and these operating signals define the operating state of the relevant affected device components 38.

[0081] For example, granulation apparatus 1 includes a blower 18, a heat source 21, a drive motor 24, a liquid pump 32, and a conveying unit 34 as influenceable device components 38. Depending on the design, granulation apparatus 1 may have any sub-combination of these influenceable device components 38, and / or have other influenceable device components 38.

[0082] The variable operating parameters of blower 18 can be volumetric flow rate, and the variable operating parameters of heat source 21 can be the temperature of the process gas that can be input via the process gas inlet. The variable operating parameter of drive motor 24 can be the rotational speed of rotor 23a. The variable operating parameters of liquid pump 32 can be the volumetric flow rate of granulating liquid and / or injection duration and / or droplet size. The variable operating parameters of feeding mechanism 33 can be, for example, the number of carrier cores that can be fed into process chamber 4.

[0083] By appropriately controlling the influenceable device component 38, the residence time (hereinafter also referred to as processing time) of the granules 12 during the ongoing granulation process can also be suitably influenced. If the granulation process is designed as a batch process according to the illustrated embodiment, the processing time can be influenced, for example, by interrupting the granulation process, which can be achieved, for example, by disabling the influenceable device component 38. In this case, in particular, an advantageous feasible solution arises: the extraction device 16 is designed as a motor-actuable configuration and is also connected to the electronic control mechanism 36 via other control lines 37 (not shown), so that the extraction device also forms an influenceable device component 38, by which the generated granules can be removed from the process chamber 4 when needed by actuating the device component.

[0084] It goes without saying that the granulation apparatus 1 can alternatively be designed to perform a continuous granulation process. In this case, once the desired performance (particularly the required particle size) is achieved, the resulting granules are continuously removed from the process chamber 4 and replaced by newly generated granules (e.g., by a continuous supply of carrier cores). Here, the processing time is determined by the residence time of the granules 12 in the process chamber 4.

[0085] The granulation unit 1 is equipped with an electrically controlled image acquisition unit 42, which can acquire two-dimensional images of the process chamber 4 during the granulation process, and further acquire two-dimensional images of the granules 11 currently undergoing granulation in the process chamber 4. These two-dimensional images can be analyzed by the electronic control mechanism 36 to be considered for setting the operating parameters of the granulation unit 1, and in particular, changing the operating parameters to adjust the operating state of the granulation process. The electrical communication line 43, indicated by the dashed line, enables the data transmission required for this purpose from the image acquisition unit 42 to the electronic control mechanism 36. For example, the electrical communication line 43 is implemented using the electromechanical connection mechanism 44 of the image acquisition unit 42, which has a plug connector to which the connecting cable extending to the electronic control mechanism 36 can be connected.

[0086] The electrical communication line 43 enables bidirectional data exchange. This allows the electronic control mechanism 36 to control the operation of the electrically controlled image acquisition unit 42, particularly its image acquisition process. Control options include, in particular, the image acquisition frequency, the time interval between successive image acquisitions, and / or the exposure time.

[0087] The ability to acquire images of the interior of process chamber 4 has significant advantages, namely, the ability to acquire images of the granules undergoing the granulation process within process chamber 4 online, that is, to acquire images directly and immediately during the granule growth process. In this way, at least near-real-time monitoring of the process flow is possible, which in turn allows for immediate process intervention to modify the process flow as needed.

[0088] Preferably, automatic image acquisition is continuously initiated by the electronic control mechanism 36 during the process, wherein if the process does not meet the standards, the electronic control mechanism 36 will cause immediate modifications by influencing one or more operating parameters. With this configuration, it is unnecessary to remove granules from the ongoing granulation process for analysis, and this is not performed in the method.

[0089] Image acquisition unit 42 includes an optoelectronic component 45, which is suitably constructed in a camera manner and defines an optical axis 46. The optoelectronic component 45 includes an image sensor 47 and a lens 48 located upstream of the image sensor 47 along the axial direction of the optical axis 46. The image sensor 47 is part of a sensor unit 49 integrated into the optoelectronic component 45, which, in addition to the image sensor 47, also has other electronic and / or mechanical components.

[0090] Optical component 45 is mounted on support structure 51 of image acquisition unit 42, which is fixed to granulation facility 2 via support structure 51 in its indicated use position. On front side 52 facing axially along optical axis 46, image acquisition unit 42 has a fixing interface, referred to as image acquisition unit-fixing interface 53 for easy identification. This fixing interface matches another fixing interface (referred to as container-fixing interface 54) provided on process container 3 of granulation facility 2, such that through the interaction of these two fixing interfaces 53 and 54, image acquisition unit 42 can be fixed or fixed to the outside of process container 3 in a particularly detachable manner when in use.

[0091] The container-fixing interface 54 is located, for example, on the outer surface 55 of the container wall 5 facing away from the process chamber 4, preferably on the side wall 25. This container-fixing interface includes, for example, a retaining ring 54a, which is welded to or screwed onto the outer surface 54 of the side wall 25. The image acquisition unit-fixing interface 53 includes a retaining flange 53a having a through hole aligned with the threaded hole of the retaining ring 54a. The retaining flange 53a is part of the support structure 51. The retaining flange 53a, and consequently the support structure 51, thus the entire image acquisition unit 42, is detachably fixed to the container wall 5 by a plurality of retaining screws 56 inserted into the through hole of the retaining flange 53a and screwed into the threaded hole of the retaining ring 54a. Here, the optical component 45 is positioned such that the optical axis 46 passes through the container wall 5, for example, the side wall 25, at a right angle, within the fixed area 57 defined by the two interacting retaining interfaces 53, 54 in the illustrated embodiment.

[0092] The image acquisition unit 42 is elongated, and its longitudinal axis 62 is, for example, in the same direction as the optical axis 46.

[0093] The image acquisition unit 42 has a light entrance 58 on its front side 52, aligned with the optical axis 46. This light entrance is suitably covered by a light-transmitting (especially transparent) front glass 61, which is particularly made of borosilicate glass. The front glass 61 is secured to the support structure 51 in a preferably replaceable manner by a retaining ring 63, for example, screwed onto a fixing flange 53a, and positioned between a retaining ring 54a and a fixing flange 53a at the point of use of the image acquisition unit 42. Here, the front glass is suitably rested against the outer surface 55, or spaced only slightly from it.

[0094] The lens 48 is located between the light entrance 58 and the sensor unit 49, wherein it is spaced apart from the light entrance 58.

[0095] In the container-fixed interface 54 region where the optical axis 46 is located, the container wall 5 is designed to be transparent. It has a transparent wall section 64 that allows unobstructed observation of the interior of the process chamber 4 from outside the process container 3, thereby observing the granules 11 currently located therein. A light entrance 58 is placed adjacent to the transparent wall section 64. In this way, the image acquisition unit 42 can acquire images of the process chamber 4 through the transparent wall section 64, and consequently, also of the granules 11 currently undergoing the granulation process within the process chamber 4. For example, the transparent wall section 64 may consist of a transparent observation window 64a, made of glass or plastic, integrated in a manner similar to a porthole into the opaque wall section 65 of the container wall 5, which, for example, forms the rest of the container wall 5. Like the rest of the container wall 5, the transparent wall section 64 is designed to be airtight.

[0096] A focal plane 66, also known as a focusing plane, is defined by the photoelectric component 45, particularly the lens 48. This focal plane is located within the space of the object to be imaged (here referring to the granular particle 12), and the points of the object are clearly imaged on the image plane defined by the image sensor 47. Preferably, the image acquisition unit 42 is equipped with a positioning mechanism 67 that allows for variable positioning of the focal plane 66 within the process chamber 4, such that the focal plane is positioned at the location where the granular particle 12 is to be optically detected. Preferably, the focal plane 66 in the process chamber 4 is located adjacent to the inner surface 68 of the container wall 5, opposite the outer surface 55, so that the external granular particles 12 passing through the fluidized bed 15 can always be clearly imaged.

[0097] The positioning mechanism 67 allows for overall adjustment of the optoelectronic assembly 45 while maintaining the relative position between the image sensor 47 and the lens 48.

[0098] As a positioning mechanism 67, for example, an electrically actuated linear module 71 is provided. This linear module has a stator 71a fixed to the support structure 51 and a carriage 71b that can linearly reciprocate relative to the stator during the positioning movement 70 indicated by the double arrows. The photoelectric component 45 is fixed to the carriage 71b. The carriage 71b is specifically designed as a slide bed. The electric drive motor 72 of the linear module 71, which cooperates with the carriage 71b, is connected to the electromechanical connection mechanism 44 via a wire 69, and then to the electronic control mechanism 36 via an electrical communication line 43. The control mechanism can thus position the focus plane 66 as needed to set the focus area.

[0099] Preferably, lens 48 is designed as a telecentric lens 48a. Preferably, the telecentric lens 48a has object-side telecentricity, wherein, for example, there exists a double telecentric lens 48a having both object-side and image-side telecentricity.

[0100] The advantage of using the telecentric lens 48a is that a constant image ratio exists on the focal plane 66, where one pixel (px) always corresponds to a specific unit of length. This provides a significant advantage in image evaluation due to the simplicity of the conversion. Therefore, the grain size can be determined when focusing on the image area. The inherently limited depth of field (e.g., 1 mm) can be easily compensated for by the positioning capability of the positioning mechanism 67, while maintaining a fixed focal length. Therefore, no measures are required for calibration or recalibration of the granulation process or method.

[0101] Sensor unit 49 is suitably equipped with a high-quality global shutter, which can close quickly. During the granulation process, image acquisition unit 42 acquires images of the granules 12 passing through the focal plane 66 at extremely high speeds according to a timing sequence set by electronic control mechanism 36, thereby reducing motion blur to a negligible level due to the short exposure time. Power is preferably supplied via PoE (Power over Ethernet), as this allows for longer cable distances compared to USB connections, which has proven particularly advantageous when integrated into large granulation equipment.

[0102] The image sensor 47 is, for example, a CCD sensor or a CMOS-based sensor. The pixel size is, for example, 4.5µm, thus achieving a good ratio between pixel size or sensor resolution and photosensitivity.

[0103] In this embodiment, the telecentric lens 48a used has a magnification of 0.735 and a depth of field of approximately 1.1 mm. This results in an effective pixel size of approximately 6.12 µm per pixel. However, other lens parameters are also feasible in principle, for example, a magnification of 1.0x with a depth of field of approximately 0.6 mm, resulting in an effective pixel size of approximately 4.5 µm / pixel. However, due to the smaller aperture cross-section, the latter would provide slightly less light to the image sensor 47.

[0104] To optimize the positioning of the photoelectric component 45, the image acquisition unit 42 is suitably equipped with at least one position sensor 73, which is fixed to the stator 71a, for example, and responds to the movement of the carriage 71b. The position sensor 73 (e.g., a limit switch) is also suitably connected to the electronic control mechanism 36 via an electrical communication line 43.

[0105] The photoelectric component 45 is appropriately fixed to the positioning mechanism 67 by a suitable fixing adapter 74, for example, fixed to its carriage 71b.

[0106] The functionally relevant components of the image acquisition unit 42 are suitably housed within and enclosed by the housing 75 of the image acquisition unit 42, thereby shielding it from the external environment. The housing 75 is, for example, fixed to the support structure 51 and is, for example, a tubular structure. Alternatively, the housing 75 may be a direct component of the support structure 51.

[0107] The image acquisition unit 42 is suitably equipped with an illumination mechanism 76 that illuminates the area of ​​the image to be captured, particularly the focal plane 66, to achieve high-quality image acquisition. For example, the illumination mechanism 76 includes a ring lamp 76a arranged coaxially with the optical axis 46, preferably located in the area of ​​the light entrance 58, and therein, particularly directly behind the optional front glass 71.

[0108] The ring lamp 76a provides uniform illumination to the focal plane 66. The ring lamp 76a has a central through-hole through which image information to be acquired can be transmitted.

[0109] Advantageously, the central aperture of the ring lamp 76a is larger than the lens diameter. In this way, the ring lamp 76a can be offset backward by 20mm to 50mm for particularly uniform illumination. The sensor unit 49 and the lens 48 can be further shifted relative to the front side 52 by about 20mm, so that the focal plane 66 has a greater distance relative to the front side 52 of the image acquisition unit 42, even when the glass of the observation window 64a is relatively thick, it is located within the process chamber 4.

[0110] Preferably, the ring lamp 76a is at least partially housed within a cooling body 77 surrounding it, which ensures optimal heat dissipation. In this way, a ring lamp 76a with high light intensity can be used.

[0111] In principle, it is advantageous that the lighting mechanism 76 is implemented using LED technology, wherein the ring light 76a is, for example, an LED ring light.

[0112] The electronic control mechanism 36 is suitable for at least largely automated operation and, for simplicity, will be referred to as control mechanism 36 below. In the illustrated embodiment, the control mechanism has a particularly advantageous construction that will be described in detail below.

[0113] The control mechanism 36 includes an electronic data processing mechanism 78, which is designed to perform image processing on the images acquired by the image acquisition unit 42. The data processing mechanism 78 is also configured to actuate the image acquisition unit 42, specifically for controlling the required image acquisition, preferably in the form of an image sequence in which images are acquired directly and sequentially in time.

[0114] The data processing unit 78 communicates with the electronic operating state setting unit 81, which is also part of the control unit 36. The operating state setting unit is connected to the influenceable device component 38 of the granulation apparatus 1 via the aforementioned signal line 37. The operating state setting unit can transmit electrical operating signals to the influenceable device component 38 via the signal line 37. These operating signals are generated in the operating state setting unit 81 based on electronic setting signals, which are provided to the operating state setting unit 81 via the data processing unit 78 according to arrow 81a.

[0115] The data processing unit 78 also communicates with the electronic output unit 82, which preferably has a display unit 82a, particularly a display, such as a monitor.

[0116] The control mechanism 36 is preferably equipped with an input mechanism 83 for applying external influences, which communicates, for example, with the data processing mechanism 78. The input mechanism 83 allows for setting parameters of the control mechanism 36, and also allows for manual training of the artificial intelligence (AI) 84, which is preferably only symbolically represented and equipped with the electronic control mechanism 36.

[0117] The input mechanism 83 can be designed for remote input using digital instruments and / or for manual keyboard input.

[0118] In order to achieve controlled operation in the closed-loop control circuit, the control mechanism 36 suitably has an electronic control mechanism 85, which is schematically shown, preferably (like artificial intelligence 84) integrated into the electronic data processing mechanism 78.

[0119] In the preferred operation of the granulation apparatus 1, a granulation method is performed, wherein image acquisition of the process chamber 4 is initiated by the data processing mechanism 78 via the image acquisition unit 42. Figure 1 Arrow 86 is used to indicate this. Image acquisition is performed online, that is, during the granulation process while the granulation facility 2 is in operation; specifically, it is performed through the transparent wall section 64 of the container wall 5. Image acquisition is performed at the focal plane 66, that is, for example, almost at the outer boundary layer of the fluidized granules 11. Each image acquisition is a snapshot of the granule particles 12 moving at high speed in front of the light entrance 58.

[0120] exist Figure 5 Part (a) schematically shows image 42a captured by image acquisition unit 42, wherein, for ease of understanding, the photographed granular particles 12 are magnified and reproduced in the selected portion. Image 42a includes the granular particles 12 located within and behind the focal plane 66.

[0121] Images captured by image acquisition unit 42 are transmitted sequentially to data processing unit 78 via communication line 43 during the granulation process, where electronic image evaluation is performed. In this image evaluation, data processing unit 78 calculates process-specific characteristic parameters related to the granules, wherein these parameters are particularly from one or more characteristic parameters of a set of characteristic parameters, including: the average particle diameter of the granules 12, the size distribution of the granules 12, and the average particle diameter.

[0122] However, in this evaluation, only the granular particles 12 located within the focal plane 66 in the corresponding image 42a are considered, if possible. For better distinction, these granular particles 12 are referred to as reference-granular particles 12a, and... Figure 5(a) In image 42a, the outline is additionally marked with a dashed line. Due to the optical design of the optoelectronic component 45 described above, the image scale of the reference particle 12a located within the focal plane 66 is known, so the particle size can be easily calculated based on the pixel size according to the actual situation.

[0123] For example, reference particles 12a for subsequent evaluation can be identified by considering image sharpness, because when using the telecentric lens 48a, the sharpness of particles 12 located outside the focal plane 66 is much lower than that of particles 12 located within the focal plane 66. The shape of the captured particles 12 can also be used as a selection criterion, based on the fact that particles 12 located within the focal plane are not obscured and therefore have a uniform and mostly approximately circular outline; while particles 12 located behind the focal plane are partially obscured, resulting in a noticeable discontinuity in their outline.

[0124] The selection process described above can be performed particularly quickly and accurately using artificial intelligence (AI) 84. The key lies in learning AI 84 to identify the reference-granule particle 12a with the highest possible accuracy. This learning or training is specifically carried out by manually labeling images of the granule 11 taken during the granulation process, or images imported via a correspondingly designed input mechanism 83, as reference-granule particles 12a using a labeling medium such as a computer mouse. With increased training time, AI 84 becomes capable of reliably identifying the reference-granule particle 12a during the actual operation of the granulation process.

[0125] The data processing unit 78, especially when using AI 84, is able to calculate the aforementioned particle-related result values ​​based on the identified reference particle 12a. For example, electronic measurements can be performed on the identified reference particle 12a, specifically its particle size and perimeter. For instance, the software can draw a closed contour line around the identified reference particle 12a (in... Figure 5 (A) is marked with a dashed outline, and the particle perimeter is calculated based on this, taking into account the original image scale (e.g., the effective pixel size per pixel is 6.12µm). The particle diameter, representing the particle size, can then be calculated from this value.

[0126] Each granulation process aims to produce granules 11 with specific properties or qualities, particularly granules 11 with a specific particle diameter "D". Since the granulation process inevitably produces granules 12 with varying particle diameters "D", the goal is generally to produce granules 11 with a predetermined average particle diameter "M", i.e., the average value. In any case, the execution of the granulation method should ensure that the calculated granule-related results correspond as closely as possible to the set target values.

[0127] The target value is stored as a comparison value or can be stored in the data processing unit 78. For example, the input unit 83 allows input of one or more target values ​​related to the aggregate.

[0128] In the control mechanism 85 (which can be implemented as part of artificial intelligence 84), during the granulation process, a comparison is made between the granulation-related result value calculated by the data processing mechanism 78 and a previously stored target value. Based on the comparison result, a setpoint signal (as mentioned) is generated and provided as an input signal to the electronic operating state setting mechanism 81 as indicated by arrow 81a. Therefore, within the control loop, the granulation-related result value serves as the controlled variable, the target value as the reference variable, and the setpoint signal as the adjustment variable for adjusting variable operating parameters. The operating state setting mechanism 81 is designed to generate an operating signal based on the obtained setpoint signal and correctly output it to the connected, influenceable device component 38, thereby modifying the operating parameters to optimize the granulation-related result value.

[0129] The output mechanism 82 can, for example, display at least the result values ​​related to the pellets based on the previous calculations of the data processing mechanism 78, which is preferably also done during the pelleting process. Figure 5 (b) shows, for example, a histogram displayed by output mechanism 82, which is based on Figure 5 Image 42a, visible in (a), reproduces the size distribution of the granular particles—here, the relationship between the number of granular particles “A” and the particle diameter “D”. The average “M” of all particle diameters “D” evaluated based on the image is also shown. Each image from image acquisition unit 42 can be displayed individually, or as the average of several images acquired sequentially. For example, the images can be evaluated periodically, and these images can be combined to form a growth curve for the entire process and visualized.

[0130] Preferably, the control mechanism 36 has a mechanically implemented or software-implemented selection switch, which allows selection of the type of granule-related result value or other process-related information that can currently be output by the output mechanism 82.

[0131] When cable connections are mentioned in relation to networking of various device components, wireless transmission systems, particularly radio-based systems, can also be used as an alternative.

[0132] In the preferred artificial intelligence (AI) 84 used in the illustrated embodiment, Mask R-CNN is employed as the algorithm. This is a convolutional neural network, or a masked convolutional neural network, which is particularly suitable for image analysis. In use, an image of the granular particles 12 is input as the study object. After evaluating the image, it outputs particle-specific dimensions, such as perimeter, area, and / or diameter, which are then used as a dataset for further processing to obtain, for example, statistical values ​​regarding the particle diameter.

[0133] This convolutional network includes a feature extractor and a classifier. The feature extractor generates an RPN (Region Proposal Network), which divides the captured image into multiple regions and evaluates these regions using probability values. Additionally, it generates ROIs (Regions of Interest)—for which multiple regions can be combined and evaluated based on object recognition probabilities for identified object categories, bounding boxes—rectangular boxes surrounding the identified particle outlines—and masks serving as labeled object regions. For the quality of the labeled object regions or identified objects (i.e., granular particles), the quantity, diversity, and quality of the training data used to train the neural network are particularly important. This training data is created manually, where input mechanism 83 can be used. For the neural network used, a pre-trained neural network, for example, that has been used for other analytical purposes, can be used, which is then preferably tuned through other training measures to perform the granulation method.

[0134] The duration of the granulation process depends on the degree of consistency between the resulting and target values ​​related to the granules. Once acceptable consistency is achieved, the granulation process is appropriately terminated or interrupted. The necessary verification can be performed using software via data processing unit 78, or alternatively or supplementarily by monitoring by an operator observing display unit 82a.

Claims

1. A granulation apparatus, comprising: Granulation facility (2), the granulation facility having a process container (3), the process container having a container wall (5) surrounding the process chamber (4), wherein, The granulation process suitable for producing granules (11) consisting of a large number of granules (12) can be carried out in the process chamber (4), and the operating status of the granulation process can be affected by the operating parameters. as well as An electronically controlled image acquisition unit (42) is used to acquire two-dimensional images of the granules (11) produced by the granulation process. These images can be analyzed in an electronic control mechanism (36) designed to set variable operating parameters for the granulation process. The feature is that the image acquisition unit (42) is arranged in the area of ​​the granulation facility (2) so that it can acquire images of the process chamber (4) during the granulation process, and then acquire online images of the granules (11) undergoing the granulation process in the process chamber (4).

2. The granulation apparatus according to claim 1, characterized in that, The granulation facility (2) is a fluidization-granulation facility that causes fluidization of the granules (11) during the granulation process.

3. The granulation apparatus according to claim 1 or 2, characterized in that, The granulation facility (2) is a fluidized bed granulator (2a).

4. The granulation apparatus according to any one of claims 1 to 3, characterized in that, The granulation facility (2) is a rotor granulator (2b) equipped with a rotor (23a) that can be rotated by a motor, especially a rotor fluidized bed granulator, wherein suitably, the rotor (23a) has a rotor plate (23) disposed in the process chamber (4).

5. The granulation apparatus according to any one of claims 1 to 4, characterized in that, The variable operating parameter of the granulation process is the residence time of the granules (12) during the continuous granulation process, which can be set in particular by starting and stopping the granulation process.

6. The granulation apparatus according to any one of claims 1 to 5, characterized in that, The granulation facility (2) has a process gas inlet (17) and a process gas outlet (22) on the process container (3). The process gas inlet is connected to the process chamber (4) and is used to input process gas. The process gas outlet is also connected to the process chamber (4) and is used to discharge the input process gas.

7. The granulation apparatus according to claim 6, characterized in that, The variable operating parameters of the granulation process are the volumetric flow rate and / or temperature of the process gas that can be input through the process gas inlet (17).

8. The granulation apparatus according to any one of claims 1 to 7, characterized in that, The granulation facility (2) has a nozzle assembly (28) designed to spray granulation liquid into the process chamber (4) of the process container (3).

9. The granulation apparatus according to claim 8, characterized in that, The variable operating parameters of the granulation process are the volumetric flow rate of the granulation liquid and / or the spray duration and / or the droplet size.

10. The granulation apparatus according to any one of claims 1 to 9, characterized in that, The granulation facility (2) has a feeding mechanism (33) for feeding a carrier core, especially in powder form, into the process chamber (4), the carrier core forming the basis of the granule structure.

11. The granulation apparatus according to claim 10, characterized in that, The variable operating parameter of the granulation process is the number of carrier cores that can be fed into the process chamber (4).

12. The granulation apparatus according to any one of claims 1 to 11, in conjunction with claim 4, characterized in that, The variable operating parameter of the granulation process is the rotational speed of the rotor (23a).

13. The granulation apparatus according to any one of claims 1 to 12, characterized in that, The container wall (5) of the process container (3) has at least one transparent wall section (64). The image acquisition unit (42) is located outside the process chamber (4) in the area of ​​the transparent wall section, so that the image acquisition unit can acquire images of the process chamber (4) through the transparent wall section (64) and then acquire images of the granules (11) located therein.

14. The granulation apparatus according to claim 13, characterized in that, The transparent section (64) of the container wall (5) is a transparent observation window (64a) made of glass, which is surrounded by the opaque section (65) of the container wall (5).

15. The granulation apparatus according to claim 13 or 14, characterized in that, The image acquisition unit (42) is fixed to the outside of the process container (3), wherein a container-fixing interface (54) matching the image acquisition unit (42) is suitably provided on the outside of the container wall (5) of the process container (3).

16. The granulation apparatus according to any one of claims 1 to 15, characterized in that, The image acquisition unit (42) has an image acquisition unit fixed interface (53) and an electromechanical connection mechanism (44). The image acquisition unit fixed interface is designed to fix the image acquisition unit relative to the process container (3). The connection mechanism is used to make an electrical connection with the electronic control mechanism (36).

17. The granulation apparatus according to any one of claims 1 to 16, characterized in that, The image acquisition unit (42) is equipped with an optoelectronic component (45), which has an image sensor (47) and a lens (48), wherein the lens (48) is preferably a telecentric lens (48a) with a preferred dual telecentric design.

18. The granulation apparatus according to claim 17, characterized in that, The lens (48) defines a focal plane (66) located within the process chamber (4) and suitably arranged adjacent to the inner surface (68) of the container wall (5) of the process container (3).

19. The granulation apparatus according to claim 17 or 18, characterized in that, The image acquisition unit (42) is equipped with a positioning mechanism (67) that enables variable positioning of the photoelectric component (45) and suitably has an electrically actuated linear module (71) that causes a change in the position of the focal plane (66) of the lens (48) and the linear module has the photoelectric component (45).

20. The granulation apparatus according to any one of claims 1 to 19, characterized in that, The image acquisition unit (42) has an illumination mechanism (76) which is configured to illuminate the area of ​​the image to be acquired in the process room (4), and specifically has a ring light (76a).

21. The granulation apparatus according to any one of claims 1 to 20, characterized in that, The image acquisition unit (42) is connected to the electronic control mechanism (36) and can control the image acquisition process through electronic image acquisition commands generated by the electronic control mechanism (36).

22. The granulation apparatus according to any one of claims 1 to 21, characterized in that, The electronic control mechanism (36) includes an electronic data processing mechanism (78) designed to perform image processing on images acquired by the image acquisition unit (42), particularly in the form of image sequences. The data processing mechanism is capable of calculating result values ​​related to the granules, such as, in particular, the average particle diameter of the granules (12) and / or the size distribution of the granules (12) and / or the average value of the particle diameter.

23. The granulation apparatus according to claim 22, characterized in that, The electronic data processing unit (78) is designed to perform image processing such that, in order to calculate the result value related to the granules, among the granules (12) visible in the acquired image, the granules (12) located on the focal plane of the image acquisition unit (42) can be identified as reference granules (12a), and the result value related to the granules can be calculated using only these identified reference granules (12a), wherein the reference granules can be electronically measured in terms of their particle size, particularly their perimeter.

24. The granulation apparatus according to claim 22 or 23, characterized in that, The control mechanism (36) of the electronic includes an operating state setting mechanism (81) of the electronic, which is designed to set variable operating parameters that affect the operating state of the granulation process based on a setting signal provided by the data processing mechanism (78) of the electronic according to the result value related to the granules.

25. The granulation apparatus according to claim 24, characterized in that, The electronic control mechanism (36) includes an adjustment mechanism (85) specifically designed as part of the electronic data processing mechanism (78). The control mechanism generates a setting signal for the electronic operating state setting mechanism (81) based on a comparison between a result value related to the pellet calculated by the data processing mechanism (78) and a pre-stored target value, wherein the target value can be suitably set separately by pre-input via the input mechanism (83) of the electronic control mechanism (36).

26. The granulation apparatus according to any one of claims 1 to 25, characterized in that, The electronic control mechanism (36) includes an electronic output mechanism (82) through which the result value related to the pellet calculated by the electronic data processing mechanism (78) can be output. The electronic output mechanism (82) includes, in particular, a display mechanism (82a) for visualizing the result value. The electronic output mechanism (82) is also suitably designed to output other process-related information.

27. The granulation apparatus according to any one of claims 1 to 26, characterized in that, The electronic control mechanism (36) is equipped with artificial intelligence (84), which is implemented in particular using a convolutional neural network.

28. A granulation method for producing granules (11) consisting of a large number of granular particles (12), wherein, In the process chamber (4) defined by the container wall (5) of the process container (3), a granulation process accompanied by particle growth is carried out. The granulation process is monitored using an electronically controlled image acquisition unit (42). The image acquisition unit performs two-dimensional image acquisition of the granules (11). The image acquisition is then evaluated by an electronic control mechanism (36) and considered for setting variable operating parameters that affect the operating state of the granulation process. The feature is that, during the granulation process, the image acquisition of the granules (11) in the process chamber (4) is performed as an online image acquisition.

29. The granulation method according to claim 28, characterized in that, The image of the granules (11) inside the process chamber (4) is acquired from outside the process chamber (4) through the transparent wall section (64) of the container wall (5) of the process container (3).

30. The granulation method according to claim 28 or 29, characterized in that, With the aid of the electronic control mechanism (36), the image acquired by the image acquisition unit (42) is processed to calculate the result value related to the granules, such as, in particular, the average particle diameter and / or size distribution and / or the average value of the particle diameter of the granules (12), wherein a setting signal is generated based on the result value specific to the granules, and the setting signal is used to specify the variable operating parameters that affect the operating state of the granulation process.

31. The granulation method according to claim 30, characterized in that, The setting signal is generated by controlling and comparing the result value related to the granules with a specified target value.

32. The granulation method according to claim 30 or 31, characterized in that, Image processing is performed such that, in order to calculate the particle-related result value, a particle (12) located on the focal plane (66) of the image acquisition unit (42) is identified from the visible particle (12) in the acquired image as a reference particle (12a), wherein only the identified reference particle (12a) is used to calculate the particle-related result value, and for this purpose, it is preferable to perform electronic measurement on its particle size, especially its perimeter.

33. The granulation method according to any one of claims 28 to 32, characterized in that, The granulation method is performed using the granulation apparatus (1) according to any one of claims 1 to 27.

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