Solid powder intelligent sample loading device

Abstract

This invention proposes an intelligent solid powder dispensing device, comprising: a closed outer shell, multiple stirring stations arranged laterally along the device inside the closed outer shell, a material station located below the stirring stations, and a controller; each stirring station includes: a first motor, a lead screw drive mechanism, a second motor, a hopper, and a stirring and dispensing shaft; the output shaft of the first motor is connected to the input end of the lead screw drive mechanism, the output end of the lead screw drive mechanism is connected to the mounting fastener of the second motor, the hopper is located at the lower end of the second motor, the stirring and dispensing shaft is connected to the output shaft of the second motor, and a feeding port is provided on one side of the hopper; the material station includes: a linear sliding module, a weighing module, and a sample dispensing bottle arranged sequentially from bottom to top. This invention solves the technical problems of manual operation error and dust exposure risk in the prior art during material dispensing. The device provided by this invention enables fully automatic, multi-channel parallel high-precision sampling, significantly improving weighing efficiency and accuracy.

Description

Technical Field

[0001] This invention relates to the field of pharmaceuticals and chemicals, and in particular to an intelligent solid powder dispensing device. Background Technology

[0002] In laboratory testing and production processes in the pharmaceutical, chemical, and other fields, solid powder dispensing is a core operation. Its dispensing accuracy, process stability, environmental adaptability, and compliance directly affect the reliability of experimental results and product quality. However, currently available solid powder dispensing devices (such as the solid powder dispensing device for testing disclosed in patent number 202322153540.0 and the adaptive solid powder dispensing device disclosed in patent number 202311736162.7) still have many technical shortcomings that urgently need to be addressed in practical applications, making it difficult to meet the requirements for high precision, high efficiency, and compliance.

[0003] First, there are significant limitations in material adaptability. For highly viscous powders such as hydroxypropyl methylcellulose, bridging is prone to occur in the hopper of existing equipment. Statistics show that this phenomenon occurs in over 30% of cases. Bridging disrupts the sample dispensing process, requiring manual tapping of the hopper by operators to clear the blockage. This not only increases labor intensity but may also introduce fluctuations in the sample dispensing volume due to manual intervention, disrupting the continuity of experiments or production.

[0004] Secondly, it is difficult to balance sampling efficiency with maintenance costs. Existing devices mostly employ a single-channel sampling design, and often require manual intervention to address issues such as "bridging," resulting in a single sampling time exceeding 3 minutes, leading to low efficiency and an inability to meet batch sampling needs. Furthermore, their spiral conveying tubes are mostly integrated structures, requiring complete replacement after wear, with a single replacement cost exceeding 2000 yuan and taking over 30 minutes, resulting in high equipment maintenance costs and long downtime. In addition, the integrated structure has poor adaptability, making it difficult to flexibly adjust to different material characteristics, further limiting the device's applicability. Summary of the Invention

[0005] To address the above issues, this invention proposes an intelligent solid powder dispensing device. This invention solves the technical problems of manual operation errors and dust exposure risks inherent in existing technologies during material dispensing. The device provided by this invention enables fully automated, multi-channel parallel, and high-precision dispensing, significantly improving weighing efficiency and accuracy.

[0006] This invention proposes a smart solid powder dispensing device, comprising:

[0007] A closed housing, multiple mixing stations arranged laterally along the device inside the closed housing, a material station located below the mixing stations, and a controller connected to the mixing stations and the material station. The mixing station includes: a first motor, a screw drive mechanism, a second motor, a hopper, and a mixing and feeding shaft; The output shaft of the first motor is connected to the input end of the lead screw drive mechanism, the output end of the lead screw drive mechanism is connected to the mounting and fixing parts of the second motor, the hopper is located at the lower end of the second motor, the stirring and feeding shaft is connected to the output shaft of the second motor, and a feeding port is provided on one side of the hopper; The material handling station includes, in sequence from bottom to top: a linear sliding module, a weighing module, and a sample dispensing bottle; When the material is being stirred, the output shaft of the first motor drives the lead screw transmission mechanism to move. The lead screw transmission mechanism converts the rotational motion of the first motor into the displacement change of the second motor. After the displacement of the second motor is adjusted to the correct position, the second motor drives the stirring and feeding shaft to move, stirring and grinding the material in the hopper. The linear sliding module drives the weighing module and the sample bottle to slide directly below the hopper. The sample bottle receives the material flowing out of the hopper, and the weighing module weighs the sample bottle. The controller controls the first motor, the second motor, the weighing module, and the linear sliding module to operate and receives signals sent by them.

[0008] In addition, the connection between the output shaft of the first motor and the input end of the lead screw transmission mechanism includes: The first motor is connected to the lead screw drive mechanism by fitting the two ends of the coupling onto the output shaft of the first motor and the input end of the lead screw drive mechanism, respectively.

[0009] In addition, a feeder is installed below the mixing and feeding shaft. The feeder rotates in the forward and reverse directions to perform different tasks, including feeding and cleaning up residual powder.

[0010] In addition, an electrostatic sensor and an ion wind neutralization device connected to the controller are integrated on the outside of the hopper's discharge port and close to the feeder. The electrostatic sensor monitors the static voltage in the discharge port area in real time. When the static voltage exceeds a preset threshold, it sends a signal to the controller, which then activates the ion wind neutralization device. The ion wind neutralization device releases positive and negative ion airflow, which directly acts on the falling material powder and the inner wall of the discharge port to neutralize the static charge on the surface of the material powder.

[0011] In addition, if the electrostatic sensor detects that the static voltage drops below a preset threshold, it sends a feedback signal to the controller, which then controls the ion wind neutralization device to automatically adjust its output power or stop working.

[0012] In addition, the device also includes an intelligent vibration compensation module, which includes: multiple vibration sensors and a mechanical counterweight module installed on the material station; The vibration data collected by the vibration sensor is transmitted to the controller. The controller's built-in adaptive PID control algorithm analyzes the amplitude, frequency, and direction of the vibration data to distinguish the vibration type. If the vibration type is internal, the operating parameters of the second motor are adjusted to counteract the vibration; if the vibration type is external, the vibration is counteracted by adjusting the weight of the mechanical counterweight module and correcting the movement trajectory of the material station.

[0013] In addition, three vibration sensors are installed at the first motor, the second motor, and the external vibration monitoring point, respectively.

[0014] In addition, vibration sensors include triaxial accelerometers and laser displacement sensors.

[0015] In addition, the controller's built-in adaptive PID control algorithm analyzes the amplitude, frequency, and direction of vibration data to distinguish vibration types, including: Kp, Ki, and Kd are automatically adjusted based on the amplitude and frequency of the vibration data using fuzzy control rules. The adaptive PID control algorithm provides feedforward compensation: based on the frequency characteristic library of the internal vibration, it outputs a reverse control signal in advance.

[0016] In addition, the controller outputs pulse signals and current signals based on the calculation results of the adaptive PID control algorithm; Pulse signals are used to control the speed and torque of the servo motor at the material handling station; The current signal is used to control the damping force of the electromagnetic damper at the material station; The servo motor dynamically corrects the movement speed and stroke of the material station based on pulse signals to compensate for trajectory deviations. The electromagnetic damper adjusts the damping coefficient according to the current signal and vibration frequency to suppress high-frequency resonance.

[0017] This invention solves the technical problems of human error and dust exposure risks during material feeding in existing technologies. The device provided by this invention enables fully automated, multi-channel parallel high-precision sample feeding, significantly improving weighing efficiency and accuracy. Attached Figure Description

[0018] Figure 1 This is an overall schematic diagram of a smart solid powder dispensing device provided in one embodiment of the present invention; Figure 2 This is a structural diagram of the stirring station in a solid powder intelligent sampling device according to an embodiment of the present invention; Figure 3 for Figure 2 A partial perspective view; Figure 4A perspective view of the stirring station in a solid powder intelligent sampling device according to an embodiment of the present invention; Figure 5 This is a structural diagram of the material station in a solid powder intelligent sampling device according to an embodiment of the present invention; Figure 6 This is a schematic diagram from one perspective of a solid powder intelligent sampling device provided in an embodiment of the present invention; Figure 7 This is a schematic diagram from another perspective of the intelligent solid powder dispensing device provided in one embodiment of the present invention. Detailed Implementation

[0019] The present invention will be further described in detail below with reference to specific embodiments and accompanying drawings. This description is intended only to illustrate specific embodiments of the invention and does not constitute any limitation on the invention. The scope of protection of the invention is defined by the claims.

[0020] Reference Figure 1 This invention proposes a smart solid powder dispensing device, comprising: 1. Enclosed housing; 2. Multiple mixing stations arranged horizontally along the device inside the enclosed housing; 3. Material station located below the mixing station; and controller connected to the mixing station 2 and the material station 3. The mixing station 2 includes: a first motor 21, a screw drive mechanism 22, a second motor 23, a hopper 24, and a mixing and feeding shaft 25; The output shaft of the first motor 21 is connected to the input end of the lead screw transmission mechanism 22, the output end of the lead screw transmission mechanism 22 is connected to the mounting and fixing parts of the second motor 23, the hopper 24 is located at the lower end of the second motor 23, the stirring and feeding shaft 25 is connected to the output shaft of the second motor 23, and a feeding port is provided on one side of the hopper 24. Material handling station 3 includes: a linear sliding module 31, a weighing module 32, and a sample dispensing bottle 33 arranged sequentially from bottom to top; When the material is being stirred, the output shaft of the first motor 21 drives the lead screw transmission mechanism 22 to move. The lead screw transmission mechanism 22 converts the rotational motion of the first motor 21 into the displacement change of the second motor 23. After the displacement of the second motor 23 is adjusted to the correct position, the second motor 23 drives the stirring and feeding shaft 25 to move, stirring and grinding the material in the hopper 24. The linear sliding module 31 drives the weighing module 32 and the sample bottle 33 to slide directly below the hopper 24. The sample bottle 33 receives the material flowing out of the hopper 24, and the weighing module 32 weighs the sample bottle 33. The controller controls the first motor 21, the second motor 22, the weighing module 32, and the linear sliding module 31 to perform actions and receives signals sent by them.

[0021] Figure 1This is an overall illustration of the device of the present invention. The enclosed outer shell 1 serves as protection, dust prevention, and structural support. Multiple stirring stations 2 are used for precise stirring and feeding of powders of different particle sizes. Optionally, the multiple stirring stations 2 are evenly arranged laterally along the device. Optionally, five stirring stations 2 are evenly arranged laterally along the device. The material station 3 is a platform for carrying sample bottles 33. The material station 3 moves as a whole to ensure that the sample bottles are precisely aligned with the outlet of the stirring station 2.

[0022] The mixing station 2 is a dual-motor coordinated feeding mechanism. Optionally, the first motor 21 is a stepper motor, the second motor 23 is a servo motor, and the mixing and feeding shaft 25 is a hexagonal mixing shaft with rounded corners.

[0023] Material station 3 includes a linear sliding module 31, a weighing module 32 and a sample bottle 33 arranged sequentially from bottom to top; the linear sliding module 31 is used to move the sample bottle 33 to align with the discharge port of the mixing station 2, and the weighing module 32 is used to weigh the sample bottle 33.

[0024] Optionally, refer to Figure 2 The overall material of the workstation has an inner wall roughness Ra≤0.8μm, which meets the GMP clean standard. Its structural design directly supports the high precision and high efficiency requirements of the multi-channel parallel sample addition device.

[0025] When the material is being stirred, the output shaft 26 of the first motor 21 drives the lead screw transmission mechanism 22 to move. The lead screw transmission mechanism 22 converts the rotational motion of the first motor 21 into the displacement change of the second motor 23. After the displacement of the second motor 23 is adjusted to the correct position, the second motor 23 drives the stirring and feeding shaft 25 to stir and grind the material in the hopper 24. The output shaft 27 of the second motor is connected to the stirring and feeding shaft 25.

[0026] Reference Figure 2 As shown, the first motor 21 is connected to the lead screw transmission mechanism 22. Optionally, the lead screw transmission mechanism 22 is a lead screw slider. The lead screw slider drives the second motor 23 to move downward. The output shaft 27 of the second motor 23 will clamp the stirring and feeding shaft 25 in the hopper 24. At this time, the second motor 23 can rotate the hopper 24 to feed materials normally.

[0027] Optionally, refer to Figure 3 As shown, the output shaft of the second motor 23 adopts a hexagonal shape with rounded corners, which facilitates the engagement when driving the rotating shaft and avoids slippage during rotation.

[0028] Optionally, refer to Figure 4 As shown, the bearing 28 and bearing pressure plate 29 limit the upper and lower positions of the mixing and feeding shaft 25 to ensure center alignment and ensure the concentricity of the three axes of the output shaft 27 of the second motor, the mixing and feeding shaft 25 and the feeder 251.

[0029] The hopper 24 has a feeding port 241 on its side for adding materials.

[0030] Since different materials have different characteristics, different feeders 251 can be set to adapt to them.

[0031] This structure can adapt to most powder materials, and has strong adaptability. Different materials are assigned to different hoppers, which can effectively avoid material contamination.

[0032] The ingenious dual-motor structure facilitates timely replacement of the material hopper, significantly improving automation. The rotational speed and stroke of the screw (25) on the mixing and feeding shaft can be precisely controlled via a second motor, achieving quantitative feeding of materials from milligrams to kilograms (with an error controllable within ±0.5%). The screw's propulsive action prevents material bridging or agglomeration, making it particularly suitable for viscous, easily agglomerated powders (such as resins and pigments). (Which part of the diagram represents the screw?) Controlled by a stepper motor, it can flexibly switch between continuous feeding and fractional feeding modes. It can handle various forms of materials such as granules, powders, and flakes, and can be adapted to materials with different densities and flowability by changing the screw or adjusting the speed.

[0033] The sealed structure design prevents dust leakage and is suitable for special environments such as explosion-proof, moisture-proof, and anti-static environments (such as chemical workshops).

[0034] After shutdown, the screw of the stirring and feeding shaft 25 can be rotated in the opposite direction to clean up residual powder, which meets clean production standards (such as ISO Class 8 cleanroom).

[0035] By incorporating sensors (such as weighing modules and photoelectric sensors), the material feeding rate can be monitored in real time and parameters can be dynamically adjusted to ensure batch-to-batch consistency. The mechanical transmission enables a precise and controllable feeding process, while also ensuring safety, cleanliness, and economy, making it particularly suitable for scenarios with stringent quality and stability requirements.

[0036] Optionally, refer to Figure 5 Material station 3 is located directly below mixing station 2. The linear sliding module 31 serves as the positioning mechanism, optionally achieving a positioning accuracy of ±0.01mm and supporting real-time speed adjustment of the servo motor. A detachable platform is provided on the linear sliding module 31 to hold the sample vials 33. Optionally, the surface of the detachable platform is equipped with an anti-slip silicone pad to prevent container displacement during sample addition. Optionally, the detachable platform is equipped with a weight sensing feedback interface linked to the weighing module. Optionally, the entire structure is made of 304 stainless steel, meeting ISO Class 8 cleanroom and GMP certification requirements. Its structural design directly ensures the accuracy, stability, and cleanliness of material reception during multi-channel sample addition, and is a key connecting link for the device to achieve a fully automated sample addition process.

[0037] Optionally, the material handling station can be set with two or more material handling stations, and the linear sliding module is an XY module. The XY module drives the sample bottle to add material at any position on the plane. The XY module is driven by a servo motor and can move the stage to the target position with micron-level accuracy (±0.01mm), ensuring that the weighing module is always aligned with the center of gravity of the material and eliminating measurement errors caused by offset.

[0038] A weighing module is located below the sample bottle. This module is characterized by high precision, easy integration, and intelligence, making it a core technology unit of modern industrial weighing systems. It not only improves production efficiency and quality control but also provides data support for predictive maintenance and energy management in intelligent manufacturing, making it a key component driving automation upgrades. It provides timely feedback, ensuring accurate precision. The closed-loop control of the feeding process, through real-time feedback and dynamic adjustment, significantly improves the precision, stability, and efficiency of industrial processes. The following are its core advantages and specific application values: 1. High precision and accuracy Real-time correction: The actual feed amount is monitored in real time by sensors (such as weighing modules and flow meters), and automatically adjusted after being compared with the target value. The error can be controlled within ±0.5%.

[0039] Strong anti-interference capability: When external factors (such as changes in material particle size or temperature fluctuations) cause deviations, the system automatically compensates. For example, when powder becomes damp, causing poor material feeding, the screw conveyor speed is automatically increased.

[0040] 2. Stability and Reliability Dynamic balance: The continuous feedback mechanism can quickly suppress disturbances and maintain the stability of the feeding rate / volume.

[0041] Example: In a chemical reactor, closed-loop control adjusts the feeding rate based on real-time pressure / temperature to prevent overflow or runaway reaction.

[0042] Redundant design: Multi-sensor fusion (such as weighing + vision inspection) improves system fault tolerance and avoids single point of failure.

[0043] 3. Safety and Compliance Preventing accidental operation: Access control + automatic verification to avoid human error settings. For example, access can be locked to prevent unauthorized modification of feeding parameters.

[0044] Compliance and traceability: Complies with GMP / ISO standards, and fully records the feeding process data (time, weight, operator) to facilitate auditing.

[0045] 4. Highly adaptable Flexibly respond to material changes: Automatically adjust parameters (such as motor speed and vibration feed amplitude) for materials with different particle sizes, densities or moisture content.

[0046] Example: In food processing, when the moisture content of flour changes, the closed-loop system automatically adjusts the screw conveyor speed to maintain a constant flow rate.

[0047] Process compatibility: Suitable for intermittent or continuous production, and supports multi-stage formula switching (such as mixing feeds with different ingredients).

[0048] like Figure 6 and 7 As shown, optionally, five mixing stations 2 are provided, each mixing station 2 is equipped with a hopper 24, so there are a total of five hoppers, which can be configured to add five different materials to ensure the diversity of materials added. The material station 3 also includes a base plate 34.

[0049] In one embodiment, the stirring station 2 is driven and prepared for feeding: After the device is started, the first motor 21 of the stirring station 2 receives a controller command and drives the C7-grade precision lead screw slider to move vertically downwards, simultaneously driving the second motor 23 to approach the bottom of the hopper. When the second motor 23 moves down to the preset position, its hexagonal output shaft 27 with rounded corners precisely engages with the stirring and feeding shaft 25 (hexagonal hole structure) of the hopper 24, with the clearance controlled at 0.05-0.1mm to ensure no slippage transmission; at this time, the feeding port of the hopper 24 is aligned with the stirring and feeding shaft 25, and the stirring and feeding shaft 25 is limited by the bearing 28 and the bearing pressure plate 29, ensuring that the output shaft 27 of the second motor 23, the stirring and feeding shaft 25, and the feeder 251 are concentric, laying the structural foundation for subsequent uniform feeding. The material powder enters the sample bottle 33 through the stirring and feeding shaft 25 and the feeder 251. Weighing closed-loop speed control and precise feeding: After feeding is initiated, the dual electronic balance sensors (accuracy 0.1mg) of the weighing module collect the weight data of the material in the sample vial 33 in real time and transmit it to the controller via the data interface. The controller, based on "real-time leveling feedback logic," compares the measured weight with the preset sample volume (i.e., the target value). When the actual weight is less than 90% of the target value, the second motor 23 is controlled to run at a higher speed (150-300 rpm) to achieve rapid material feeding; When the actual measured weight reaches 90%-99% of the target value, the speed of the second motor 23 is reduced to 50-100 rpm to slow down the feeding speed. When the measured weight reaches 99%-100% of the target value, the speed of the second motor 23 is further reduced to 10-20 rpm to avoid exceeding the target. The entire process is controlled through a closed loop of "weight feedback - speed adjustment - material feeding correction" to ensure that the single sample addition error is ≤ ±0.5%, meeting the requirements for high-precision sample addition.

[0050] XY Module Drive and Multi-Material Ratio Sampling: After a single sampling bottle 33 completes the first material sampling, the control unit sends a displacement command to the XY module (positioning accuracy ±0.01mm) at the material station: The XY module drives the stage (carrying sample vial 33) to move along the X-axis, precisely aligning it with the discharge port of the next stirring station (station spacing 100mm, displacement deviation <0.01mm). Repeat steps 1-2 to complete the addition of the second material. The controller can adjust the speed of the second motor and the feeding time according to the preset formula to achieve the ratio control of different materials (e.g., material A: material B: material C = 5:3:2). The process is repeated until the sample bottle has been filled with five different materials in proportion. The entire process requires no manual intervention. The total time for adding multiple materials to a single bottle is ≤2 minutes, which is more than 4 times more efficient than a single-channel device. Furthermore, the independent hopper and reverse cleaning design prevent cross-contamination of materials.

[0051] The test data are as follows: 1. Accuracy test: Sample amount 50mg, n=20 times, mean error 0.42%, standard deviation 0.08%, repeatability RSD=0.35% (difference between the two sensors <0.1mg); 2. Efficiency test: Single-channel sample addition takes 42 seconds per run, and 5 channels process 5 kinds of materials (50mg each) in parallel, with a total time of 45 seconds, which is 6.7 times more efficient than the existing technology (2.5 minutes per channel); 3. Residue test: Using polyethylene powder (easily electrostatic), n=30 times, the average residue rate was 0.08%, with a maximum of 0.1%, which is far lower than the existing technology's 5.2%; 4. Environmental testing: High temperature and high humidity (35℃ / 70% RH): 50mg, with a sampling error of 0.45%; Vibration environment (0.1g / 50Hz): Error 0.42%; Low temperature and low humidity (10℃ / 30% RH): error 0.40%, all meeting ±0.5% requirements; 5. Long-term operation test: 1000 batches (50mg / batch) were processed continuously for 24 hours without failure, with an error range of 0.35%-0.45%, and the data storage was complete and exportable.

[0052] The present invention is compared with the prior art device in several parameters as follows: Vibration interference: Under normal laboratory conditions (personnel movement, equipment operation), the weighing data of this device fluctuates within ±0.8mg (the fluctuation range of this invention is ±0.1mg), resulting in a small-dose (<10mg) sample addition error exceeding ±3%; Static electricity residue: After the metal spiral conveying tube rubs against the polyethylene powder, the static voltage can reach 500V, and the amount of powder adhering to it accounts for 5.2% of the total sample (after neutralization by ion wind, the static voltage is <50V and the amount of powder adhering to it is 0.08%). High maintenance costs: Its spiral conveyor tube is an integrated structure, which needs to be replaced as a whole after wear (replacement cost > 2000 yuan / time), and the replacement time is > 30 minutes. The modular design of this invention allows for the replacement of the feeder separately (cost < 500 yuan / time, replacement time < 5 minutes).

[0053] This invention solves the technical problems of existing devices, such as low sample addition accuracy (error ±1.2%) due to vibration; high powder residue rate (>5%) due to electrostatic adsorption, which easily leads to cross-contamination; low sample addition efficiency (>3 minutes per session) due to single channel and manual intervention; poor adaptability and high maintenance costs due to lack of modular design; and lack of data traceability, which does not meet GMP compliance requirements.

[0054] Beneficial technical effects of the present invention: Ensuring cleanliness, safety, and compliance: To meet the sterile and dust-free environment requirements under certification systems such as GMP and GSP, the core of the solution adopts a forward-looking anti-contamination design.

[0055] Achieving high-efficiency automation and intelligence: To improve efficiency and reduce reliance on skilled operators, the system is equipped with a high-speed motion control module and intelligent scheduling algorithms. It supports simultaneous operation of multiple channels and rapid switching between micro-plate mode, and can optimize sample loading processes and paths with a single click, reducing batch sample processing time by several times. Combined with a user-friendly graphical software interface, it allows for flexible editing, saving, and recall of complex experimental procedures, greatly enhancing the reproducibility and automation of experiments.

[0056] Improving Dosing Accuracy and Stability: Addressing the issues of powder adhesion, residue, and volume deviation caused by equipment vibration and environmental static electricity in existing technologies, this solution employs an active vibration damping system to effectively isolate internal and external vibration sources. Simultaneously, it integrates a high-sensitivity electrostatic sensor and an ion wind neutralization device to monitor and eliminate static charge on the feed head in real time, ensuring consistent powder dosing and release, thereby elevating dosing accuracy (CV value) to a new level.

[0057] Main invention steps: Intelligent vibration compensation module: It adopts a strategy that combines mechanical counterweight and electronic balance, and incorporates an adaptive PID control algorithm. It can monitor and dynamically adjust the movement trajectory of materials at the workstation in real time, effectively offsetting internal and external vibrations and ensuring the stability of the moving end.

[0058] High-precision closed-loop quality feedback system: It integrates dual electronic balance sensors for redundancy verification, performs real-time weighing monitoring for each sample addition, and feeds the data back to the control system to automatically correct the sample addition parameters, ensuring extremely high sample addition accuracy and repeatability.

[0059] Fully modular design: The functional units are highly integrated, supporting the quick replacement and identification of powder containers and conveyor heads of different specifications. Switching can be completed without tools, which greatly improves the equipment's multi-application adaptability and maintenance efficiency.

[0060] One set of process parameters for this invention is as follows: The positioning accuracy of the XY module is ±0.01mm; Voltage <50V after static electricity is eliminated; Cleaning reverse speed 100 rpm, time 5 seconds; Add sample volume 0.1mg-100g, rotation speed 50-300rpm (according to dosage segment).

[0061] Experimental data: Accuracy: n=100 times, mean error 0.38%, standard deviation 0.08%; Efficiency: 42 seconds for a single sample addition, 400 batches per hour processed in parallel by 5 channels; Residue: n=50 times, average residue rate 0.08%; Stability: After 24 hours of continuous operation, the error range is 0.35%-0.45%, and the failure rate is 0%. Environmental adaptability: 0.45% error at 35℃ / 70% RH, and 0.42% error under 0.1g vibration.

[0062] This invention solves the technical problems of human error and dust exposure risks during material feeding in existing technologies. The device provided by this invention enables fully automated, multi-channel parallel high-precision sample feeding, significantly improving weighing efficiency and accuracy.

[0063] In one embodiment, the connection between the output shaft of the first motor and the input end of the lead screw drive mechanism includes: The first motor is connected to the lead screw drive mechanism by fitting the two ends of the coupling onto the output shaft of the first motor and the input end of the lead screw drive mechanism, respectively.

[0064] In this embodiment, the output shaft of the first motor is connected to the lead screw transmission mechanism via a coupling, thereby enabling power transmission.

[0065] In one embodiment, a feeder 251 is also installed below the mixing and feeding shaft 25. The feeder 251 rotates in the forward and reverse directions to perform different tasks, including feeding and cleaning up residual powder.

[0066] The feeder 251 pushes the powder in the hopper forward (downward) to achieve controllable and continuous quantitative feeding. Different shapes and rotation speeds of the feeder 251 can prevent bridging and adapt to different material characteristics.

[0067] The feeder 251 is installed at the end of the mixing feed shaft 25. Its function is to directly contact the powder material and to efficiently and controllably convert the rotational motion of the screw (mixing feed shaft) into the conveying or cleaning action of the powder.

[0068] Existing technologies suffer from problems such as cross-contamination due to powder residue and inconvenient device maintenance. In this embodiment, after completing a sample addition task or before changing materials, the feeder 251 is controlled to rotate in the reverse direction. At this time, its movement direction can reverse the residual powder adhering to the pipe wall, threads, or blades back into the hopper, or clear the residual material through a specific venting path, while simultaneously clearing a clean channel for the next material, ensuring batch-to-batch purity; recovering residual powder improves material utilization; and eliminating the need for manual disassembly and cleaning, meeting the design requirements of fully automated, high-throughput equipment.

[0069] In one embodiment, an electrostatic sensor and an ion wind neutralization device connected to the controller are integrated on the outside of the discharge port of the hopper 24 and adjacent to the feeder. The electrostatic sensor monitors the static voltage in the discharge port area in real time. When the static voltage exceeds a preset threshold, it sends a signal to the controller. The controller then activates the ion wind neutralization device, which releases positive and negative ion airflow. The positive and negative ion airflow directly acts on the falling material powder and the inner wall of the discharge port to neutralize the static charge on the surface of the material powder.

[0070] The existing technology still has the following technical problems: Existing devices also have shortcomings in terms of environmental adaptability and weighing accuracy. In a typical laboratory environment, external vibrations caused by personnel movement and equipment operation can interfere with the weighing system, resulting in weighing data fluctuations as high as ±0.8mg. In small-dose sample addition scenarios below 10mg, the resulting error rate exceeds ±3%, and the overall addition error of some devices even reaches ±1.2%, making it difficult to meet high-precision requirements. Simultaneously, in high-temperature and high-humidity environments (humidity > 60%, temperature > 30℃), the weighing sensors are prone to drift, with drift exceeding 0.5mg, leading to data distortion and unstable operation. Furthermore, existing devices use metal spiral conveying tubes, which are prone to generating static electricity when rubbing against powders such as polyethylene. The static voltage can reach 500V, causing a large amount of powder to adhere to the tube wall, with the adhered amount accounting for up to 5.2% of the total added sample. This not only leads to material waste but may also cause cross-contamination between batches, affecting experimental consistency or product quality.

[0071] Therefore, in this embodiment, an electrostatic sensor and an ion wind neutralization device connected to the controller are integrated on the outside of the hopper's discharge port and close to the feeder. The electrostatic sensor monitors the static voltage in the discharge port area in real time. When the static voltage exceeds a preset threshold, it sends a signal to the controller, which then activates the ion wind neutralization device. The ion wind neutralization device releases positive and negative ion airflow, which directly acts on the falling material powder and the inner wall of the discharge port to neutralize the static charge on the surface of the material powder and also suppress the generation of new static electricity.

[0072] Electrostatic monitoring and elimination process: The electrostatic sensor monitors the static voltage in the feed port area in real time, with a monitoring range of 0-1000V and a response time of ≤0.1 seconds, accurately capturing the static electricity generated by the friction between the powder and the conveying pipe.

[0073] When the detected static voltage exceeds 50V (preset threshold), the controller immediately activates the ion wind neutralization device. The ion wind neutralization device releases a stream of positive and negative ions, which directly act on the falling powder and the inner wall of the feed inlet, neutralizing the static charge on the powder surface and suppressing the generation of new static electricity. The static voltage sensor continuously feeds back monitoring data until the static voltage drops below 50V. At this point, the ion wind neutralization device automatically adjusts its output power or stops operating, ensuring that the powder adhesion is controlled within 0.08%, avoiding sample addition errors and residual contamination caused by static electricity.

[0074] In one embodiment, if the electrostatic sensor detects that the static voltage drops below a preset threshold, it sends a feedback signal to the controller, which then controls the ion wind neutralization device to automatically adjust its output power or stop working.

[0075] The preset threshold is, for example, 50V. When the static electricity decreases, the power can be reduced or the operation can be stopped to reduce workload. The output power is automatically adjusted or the operation is stopped by the ion wind neutralization device to ensure that the powder adhesion is controlled within 0.08%, avoiding sample addition errors and residual contamination caused by static electricity.

[0076] In one embodiment, the device further includes an intelligent vibration compensation module, which includes: multiple vibration sensors and a mechanical counterweight module disposed on the material station; The vibration data collected by the vibration sensor is transmitted to the controller. The controller's built-in adaptive PID control algorithm analyzes the amplitude, frequency, and direction of the vibration data to distinguish the vibration type. If the vibration type is internal, the operating parameters of the second motor are adjusted to counteract the vibration; if the vibration type is external, the vibration is counteracted by adjusting the weight of the mechanical counterweight module and correcting the movement trajectory of the material station.

[0077] To address the issues of powder adhesion, residue, and volume deviation caused by equipment vibration and environmental static electricity in existing technologies, this embodiment employs active vibration reduction to effectively isolate internal and external vibration sources.

[0078] This embodiment analyzes the amplitude, frequency, and direction of vibration data using the adaptive PID control algorithm built into the controller, thereby distinguishing the vibration type. If the vibration type is internal vibration, the operating parameters of the second motor are adjusted to counteract the vibration; if the vibration type is external vibration, the vibration is counteracted by adjusting the weight of the mechanical counterweight module and correcting the movement trajectory of the material station.

[0079] Monitoring mechanism: Vibration sensors collect vibration data in real time, including vibrations in the laboratory environment (personnel movement, equipment operation) and vibrations inside the device (motor operation, material feeding impact). The sampling frequency is 100Hz, which can capture minute vibrations greater than 0.01g.

[0080] The collected vibration data is transmitted to the controller's adaptive PID control algorithm. The algorithm quickly analyzes the amplitude, frequency, and direction of the vibration, and distinguishes between internal and external vibration types.

[0081] The dynamic adjustment compensation strategy is designed for different vibration sources: internal vibrations are offset by adjusting motor operating parameters (such as reducing speed fluctuations), while external vibrations are offset by fine-tuning the mechanical counterweight module (such as counterweight displacement) and correcting the movement trajectory of the material station, thus offsetting the impact of vibrations on the sampling accuracy and ensuring that the fluctuation range of weighing data is controlled within ±0.1mg.

[0082] Adaptive PID control algorithms primarily differentiate between internal and external vibration sources through sensor deployment, data feature analysis, and machine learning models. Optionally, vibration sensors are deployed at fixed locations on the frame to monitor environmental vibrations (external sources); vibration sensors are installed on moving parts such as motors, material handling stations, and mixing / feeding shafts to monitor internal vibrations (internal sources). By distinguishing their locations, the direction of the vibration source can be preliminarily determined.

[0083] Vibration characteristic analysis: Internal vibrations typically exhibit specific frequency and periodic characteristics related to motor speed, screw rotation, and material feeding impact; external vibrations (such as personnel movement and other equipment operation) are characterized by low frequency, randomness, and non-periodicity. The algorithm quickly extracts the spectral characteristics of the vibration signal and further distinguishes the source by combining the vibration direction (such as axial and radial).

[0084] Machine learning and operating condition judgment: A database of typical operating conditions (such as motor start-up and shutdown, sampling actions, etc.) is preset. Through real-time data matching and classification models, it is determined whether the current vibration is synchronized with the action of the internal actuator. If the vibration characteristics are unrelated to the internal action and the direction is chaotic, it is judged as external vibration.

[0085] While the device's own sensors can detect external vibrations, this is precisely the prerequisite for implementing active compensation. The sensor's role is "sensing," while adjusting the counterweight and correcting the trajectory is "execution," together forming a closed-loop control. Differences in the source of external vibrations: External vibrations (such as personnel movement, environmental equipment interference) act on the frame or the foundation of the entire device, and their energy is transferred to the material handling station through the structure. This type of vibration cannot be directly eliminated by adjusting the internal motor parameters because its source is outside the system and is uncontrollable.

[0086] The specificity of the compensation strategy: After the vibration signals monitored in real time by the sensors at the material handling station are analyzed by the algorithm and identified as external vibrations, the control system will activate two compensation mechanisms: One method is mechanical counterweight adjustment: by finely adjusting the position of the counterweight (such as by using an electric slide table to adjust the counterweight distance), the moment of inertia and dynamic balance of the material station are changed, making it more stable under external excitation.

[0087] Another approach is real-time trajectory correction: based on the displacement deviation fed back by vibration sensors, an adaptive PID control algorithm dynamically generates reverse motion commands to drive the servo motor at the material station to perform high-frequency fine-tuning, thus offsetting the path deviation caused by external vibration.

[0088] The core role of sensor data: Vibration sensors at the material handling station, such as accelerometers and displacement sensors, provide firsthand vibration data, enabling the differentiation between externally transmitted vibrations and internal movements, and quantifying the amplitude and direction of the vibrations. Without this real-time data, counterweight adjustments and trajectory corrections would lack a basis, making precise offsetting impossible.

[0089] Therefore, vibration sensors are designed to achieve integrated active vibration compensation that combines "sensing, decision-making, and execution." In particular, for external vibrations, they need to change their own dynamic characteristics or motion path to counteract external interference and thus ensure the accuracy of sample loading.

[0090] In one embodiment, three vibration sensors are installed at the first motor, the second motor, and an external vibration monitoring point, respectively. By monitoring the vibration at these locations, both internal and external vibrations can be comprehensively monitored.

[0091] In one embodiment, the vibration sensor types include a triaxial accelerometer and a laser displacement sensor. Using both types of sensors makes the measurements more accurate.

[0092] In one embodiment, the controller's built-in adaptive PID control algorithm analyzes the amplitude, frequency, and direction of the vibration data to distinguish vibration types, including: Kp, Ki, and Kd are automatically adjusted based on the amplitude and frequency of the vibration data using fuzzy control rules. The adaptive PID control algorithm provides feedforward compensation: based on the frequency characteristic library of the internal vibration, it outputs a reverse control signal in advance.

[0093] In adaptive PID control algorithms, mechanical counterweights are the "basic defense" for vibration compensation. Their core function is to balance the inertial force of the material station and reduce the generation of internal vibrations.

[0094] Counterweight design logic: The counterweight is made of high-density tungsten alloy, which is small in size and concentrated in mass, avoiding increasing the overall load on the material handling station. The counterweight mass and installation position are determined through dynamic calculations: Based on the total mass of the material handling station (denoted as m1) and the center of gravity position (denoted as L1), the counterweight mass m2 is configured so that m1×L1=m2×L2 (L2 is the distance from the counterweight to the rotation axis of the material handling station), achieving static torque balance.

[0095] Passive offsetting effect: For the material station's "acceleration-uniform speed-deceleration" motion process, the counterweight generates a reverse inertial force to offset the material station's own centrifugal force and impact load.

[0096] The electronic balancing system is the "sensing center" of vibration compensation. Its core function is to capture residual vibration signals in real time, providing data support for active correction and covering all scenarios of internal and external vibration sources. The sensor configuration and data acquisition are as follows: Sensor Type: Two sets of high-precision MEMS triaxial accelerometers and one set of laser displacement sensor are used. Installation Location: Accelerometer 1 is installed on the material handling unit to monitor overall vibration; Accelerometer 2 is installed inside the end effector, i.e., the linear sliding module, to directly monitor the vibration of the sample bottle; The laser displacement sensor is fixed to the linear sliding module, aligned with the reference point of the end effector (the center point of the linear sliding module), to monitor absolute displacement deviation. Data Preprocessing: The collected vibration signals (acceleration, displacement) are processed by a filtering algorithm (Kalman filter + low-pass filter) to remove environmental electromagnetic interference and sensor noise, extracting effective vibration features (amplitude, frequency, phase).

[0097] The adaptive PID controller is the "decision and execution core" of vibration compensation. Its core function is to dynamically adjust the control parameters based on the sensed vibration deviation, drive the actuator to correct the motion trajectory, and counteract residual vibration.

[0098] Ordinary PID controllers have fixed parameters and cannot adapt to dynamic changes in vibration frequency and amplitude. Adaptive PID controllers achieve dynamic adjustment through the following mechanism: Parameter self-tuning: Based on the frequency and amplitude of the vibration signal, Kp, Ki, and Kd are automatically adjusted through fuzzy control rules (preset with a library of 10 typical operating condition parameters). For example: Low-frequency large-amplitude vibration (such as frame resonance): Increase Kp and decrease Ki to quickly offset the deviation. High-frequency small-amplitude vibration (such as screw rotation disturbance): Decrease Kp and increase Kd to suppress high-frequency jitter. Feedforward compensation: Combining the frequency characteristic library of internal vibration, a reverse control signal is output in advance. For example, when the screw rotates, the servo motor is driven in advance to generate reverse torque, realizing "predictive compensation", which is 30% faster than simple feedback correction.

[0099] In one embodiment, the controller outputs pulse signals and current signals based on the calculation results of the adaptive PID control algorithm; Pulse signals are used to control the speed and torque of the servo motor at the material handling station; The current signal is used to control the damping force of the electromagnetic damper at the material station; The servo motor dynamically corrects the movement speed and stroke of the material station based on pulse signals to compensate for trajectory deviations. The electromagnetic damper adjusts the damping coefficient according to the current signal and vibration frequency to suppress high-frequency resonance.

[0100] Controller output: Based on the calculation results, it outputs pulse signals (to control the servo motor speed and torque) and current signals (to control the damping force of the electromagnetic damper). Servo motor: Dynamically corrects the movement speed and stroke of the material station to compensate for trajectory deviations. Electromagnetic damper: Adjusts the damping coefficient according to the vibration frequency to suppress high-frequency resonance. This embodiment achieves a perfect closed-loop control system.

[0101] In one embodiment, the controller adds data storage and import / export functions. The lack of data traceability in existing technologies makes it difficult for current devices to meet stringent compliance requirements. Most existing technologies do not integrate data storage and export functions, failing to automatically record key information for each batch of samples, such as time, weight, operator, and equipment parameters. In strictly regulated fields such as pharmaceuticals, this deficiency results in a lack of complete traceability in the sampling process. In the event of quality problems, it is impossible to quickly trace and attribute the cause, failing to meet the core requirements of "traceability" in Good Manufacturing Practices (GMP). Therefore, this embodiment solves this technical problem. This embodiment can also add a software interface to display various parameters of the device and operation, while also providing interactive functions to facilitate operator input of instructions.

[0102] In one embodiment, the material handling station has two sample bottle racks of different sizes. The lower part of the sample bottle racks can move back and forth, allowing the different sized sample bottle racks to be aligned directly below the mixing station as needed. The mixing and feeding shaft is a hexagonal mixing shaft with rounded corners.

[0103] Example of "mixed addition of 5 active pharmaceutical ingredients (APIs)" in pharmaceutical research and development: 1. Requirements: 5 types of APIs (50mg each, error ≤ ±0.5%), avoiding cross-contamination, 100 batches to be completed within 1 hour; 2. Implementation: (1) Loading: 5 hoppers are used to load 5 types of API, which are compatible with screw feeders; (2) Parameters: Set the sample volume to 50mg, the rotation speed to 150rpm, clean once, and start the multi-channel parallel mode; (3) Sample addition: The XY module positions the sample bottle, motor 1 drives motor 2 to engage the stirring shaft, vibration compensation (speed reduction of 10% when vibration > 0.05g), static elimination (voltage > 100V triggers ion wind), weighing feedback reaches 45mg and the speed is reduced to 50rpm, 49.5mg and the speed is reduced to 10rpm; (4) Completion: 90 seconds per batch, 400 batches processed per hour (exceeding demand), average error of 0.40%, residual rate of 0.07%, data is automatically stored, and meets GMP traceability requirements.

[0104] Using existing technology CN202410024624.0, an automated solid powder dispenser device adapted to an electronic balance, the same experiment of "mixed dispensing of 50mg each of 5 APIs" was conducted: 1. Accuracy: The mean error of a single API sample is 1.58%, and the standard deviation is 0.65%. The total error after mixing five APIs exceeds ±8%, which is much higher than the 0.40% of this invention. 2. Efficiency: Single-channel sample loading requires 2.5 minutes per API, totaling 12.5 minutes per batch for 5 APIs, resulting in only 4.8 batches processed per hour, which is 1.2% of the efficiency of this invention (800 batches / hour). 3. Residue: Without electrostatic elimination, the API residue rate was 4.8%, leading to cross-contamination and increasing the error of subsequent batches to 2.3%. 4. Maintenance: After 100 batches, the spiral tube will wear out and need to be replaced, costing 2200 yuan and taking 35 minutes. This invention does not require maintenance. 5. Compliance: It lacks data storage functionality, making it impossible to trace the sampling information for each batch, which does not meet GMP requirements.

[0105] The test examples are as follows: 1. Test conditions: Standard laboratory environment (25℃ / 50% RH, 0.08g vibration from personnel movement), the test materials are 5 pharmaceutical APIs (A: lactose, B: hydroxypropyl methylcellulose, C: magnesium stearate, D: microcrystalline cellulose, E: mannitol), and the sample dosage for each target is 50mg.

[0106] 2. Testing equipment: The device of this invention (experimental group) and CN202410024624.0 An automated solid powder sampler device adapted to an electronic balance (control group).

[0107] 3. Test steps: (1) Experimental group: ① Device self-test → ② Set 5-channel parallel parameters → ③ XY module positioning → ④ Dual motor drive feeding (vibration compensation + static elimination) → ⑤ Closed-loop correction → ⑥ Clean storage, repeat 100 batches; (2) Control group: ① Manually calibrate the hopper → ② Single-channel feeding → ③ Manually record data → ④ Disassemble and clean, repeat 100 batches.

[0108]

[0109] The above description is merely the principle and preferred embodiment of the present invention. It should be noted that, for those skilled in the art, several other modifications can be made based on the principle of the present invention, and these modifications should also be considered within the scope of protection of the present invention.

Claims

1. A smart solid powder dispensing device, characterized in that, include: A closed housing, multiple mixing stations arranged laterally along the device inside the closed housing, a material station located below the mixing stations, and a controller connected to the mixing stations and the material station. The mixing station includes: a first motor, a screw drive mechanism, a second motor, a hopper, and a mixing and feeding shaft; The output shaft of the first motor is connected to the input end of the lead screw drive mechanism, the output end of the lead screw drive mechanism is connected to the mounting and fixing parts of the second motor, the hopper is located at the lower end of the second motor, the stirring and feeding shaft is connected to the output shaft of the second motor, and a feeding port is provided on one side of the hopper; The material handling station includes, in sequence from bottom to top: a linear sliding module, a weighing module, and a sample dispensing bottle; When the material is being stirred, the output shaft of the first motor drives the lead screw transmission mechanism to move. The lead screw transmission mechanism converts the rotational motion of the first motor into the displacement change of the second motor. After the displacement of the second motor is adjusted to the correct position, the second motor drives the stirring and feeding shaft to move, stirring and grinding the material in the hopper. The linear sliding module drives the weighing module and the sample bottle to slide directly below the hopper. The sample bottle receives the material flowing out of the hopper, and the weighing module weighs the sample bottle. The controller controls the first motor, the second motor, the weighing module, and the linear sliding module to operate and receives signals sent by them.

2. The intelligent solid powder dispensing device according to claim 1, characterized in that, The connection between the output shaft of the first motor and the input end of the lead screw transmission mechanism includes: The first motor is connected to the lead screw drive mechanism by fitting the two ends of the coupling onto the output shaft of the first motor and the input end of the lead screw drive mechanism, respectively.

3. The intelligent solid powder dispensing device according to claim 1, characterized in that, Below the mixing and feeding shaft is a feeder. The feeder rotates in both directions to perform different tasks, including feeding and cleaning up residual powder.

4. The intelligent solid powder dispensing device according to claim 1, characterized in that, An electrostatic sensor and an ion wind neutralization device connected to the controller are integrated on the outside of the hopper's discharge port and close to the feeder. The electrostatic sensor monitors the static voltage in the discharge port area in real time. When the static voltage exceeds a preset threshold, it sends a signal to the controller, which then activates the ion wind neutralization device. The ion wind neutralization device releases positive and negative ion airflow, which directly acts on the falling material powder and the inner wall of the discharge port to neutralize the static charge on the surface of the material powder.

5. The intelligent solid powder dispensing device according to claim 4, characterized in that, If the electrostatic sensor detects that the static voltage drops below a preset threshold, it sends a feedback signal to the controller, which then controls the ion wind neutralization device to automatically adjust its output power or stop working.

6. The intelligent solid powder dispensing device according to claim 4, characterized in that, The device also includes an intelligent vibration compensation module, which includes: multiple vibration sensors and a mechanical counterweight module installed at the material station; The vibration data collected by the vibration sensor is transmitted to the controller. The controller's built-in adaptive PID control algorithm analyzes the amplitude, frequency, and direction of the vibration data to distinguish the vibration type. If the vibration type is internal, the operating parameters of the second motor are adjusted to counteract the vibration; if the vibration type is external, the vibration is counteracted by adjusting the weight of the mechanical counterweight module and correcting the movement trajectory of the material station.

7. The intelligent solid powder dispensing device according to claim 6, characterized in that, Three vibration sensors are installed at the first motor, the second motor, and the external vibration monitoring point, respectively.

8. The intelligent solid powder dispensing device according to claim 6, characterized in that, Vibration sensors include triaxial accelerometers and laser displacement sensors.

9. The intelligent solid powder dispensing device according to claim 6, characterized in that, The controller's built-in adaptive PID control algorithm analyzes the amplitude, frequency, and direction of vibration data to distinguish vibration types, including: Kp, Ki, and Kd are automatically adjusted based on the amplitude and frequency of the vibration data using fuzzy control rules. The adaptive PID control algorithm provides feedforward compensation: based on the frequency characteristic library of the internal vibration, it outputs a reverse control signal in advance.

10. The intelligent solid powder dispensing device according to claim 6, characterized in that, The controller outputs pulse signals and current signals based on the calculation results of the adaptive PID control algorithm; Pulse signals are used to control the speed and torque of the servo motor at the material handling station; The current signal is used to control the damping force of the electromagnetic damper at the material station; The servo motor dynamically corrects the movement speed and stroke of the material station based on pulse signals to compensate for trajectory deviations. The electromagnetic damper adjusts the damping coefficient according to the current signal and vibration frequency to suppress high-frequency resonance.

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