Granulation apparatus and granulation method

Abstract

A granulation apparatus (1) is proposed, which has a granulation machine (2), the granulation machine (2) is equipped with a process container (3), and the process container (3) has a container wall (5) surrounding a process chamber (4). A granulation process can be carried out in the process chamber (4) to produce granules (11) consisting of a large number of granular particles (12), and the operating state of the granulation process can be influenced by variable operating parameters. An image acquisition unit (42) is positioned in the area of ​​the granulation machine (2) so that the image acquisition unit (42) can capture images of the process chamber (4) during the granulation process, and consequently, images of the granules (11) undergoing the granulation process in the process chamber (4). This allows for reliable monitoring of the granulation process. Furthermore, a granulation method is proposed that uses inline image acquisition of the process chamber (4), which is carried out while using the granulation apparatus.

Description

Technical Field

[0001] The present invention relates to a granulation apparatus comprising a granulation machine, wherein the granulation machine has a process vessel provided with a vessel wall surrounding a process chamber, a granulation process suitable for producing granules consisting of a large number of granule particles can be carried out in the process chamber, the operating state of the granulation process can be influenced by operating parameters, the granulation apparatus comprises an electrically operable image capturing unit for capturing two-dimensional images of granules producible by the granulation process, and these two-dimensional images can be evaluated in an electronic control device configured to set variable operating parameters for the granulation process.

[0002] The present invention further relates to a granulation method for producing granules consisting of a large number of granule particles, which can be carried out particularly using a granulation apparatus of the type mentioned at the beginning, wherein a granulation process involving particle growth is carried out in a process chamber of a process vessel defined by a vessel wall, the granulation process is monitored while using an electrically operable image capturing unit, the image capturing unit captures two-dimensional images of the granules, the images are then evaluated using an electronic control device, and the evaluation of the images is used to set variable operating parameters that influence the operating state of the granulation process.

[0003] A granulation apparatus configured and operational as described above is known based on Patent Document 1. In Patent Document 1, the granulation apparatus has a granulation section including a granulation drum, to which a drop chute with a funnel is positioned. The granules formed in the granulation section are continuously supplied vertically to this drop chute from the inlet side. The granules thus obtained are removed at a sample removal opening in the drop chute and supplied to a field unit equipped with a color camera. The granules fall downwards in the objective plane of the color camera, and a series of images of the falling granules are captured during this fall. While the series of images are being captured, the particle size and particle size distribution are determined using the color camera according to the projected particle area. In a subsequent calculation unit, the captured series of images are analyzed and digitally processed, so that the series of images are displayed on an output device, for example, a monitor. Furthermore, the calculation unit determines process-specific parameters. These parameters serve as input variables for an equipment regulator having a fuzzy logic block. After comparison with a target value, an output signal is generated, which can then influence the operating parameters of the granulation process to obtain the desired product quality. Continuous image capture can be performed within the field unit, as well as directly on the granular particles falling from the granulation section into the drop chute. Known granulation apparatuses can be used to manufacture, for example, fertilizers and pharmaceutical products.

[0004] Patent Document 2 describes a method and apparatus for producing granular solid particles. The produced particles are detected by an optical detection system, and at least one parameter of the produced particles is identified based on the optically detected data of the produced particles. Then, based on the identified parameter, at least one parameter of the production process of another particle is automatically influenced. Optical detection of the particles is performed after they leave the process vessel in which the granulation process takes place. The process vessel is equipped with, for example, a granulation disk, and the rotational motion of this granulation disk causes aggregation of the supplied starting material. Control data is generated using an electronic control device, for example, implemented by a computer. The control data is used to optimize the subsequent granulation process, for example, to control a valve assembly that affects the supply of starting material for the granulation process.

[0005] Regardless of the prior art described above, the applicant possesses internal knowledge of pelletizing equipment. In this pelletizing equipment, pelletized granules are produced using a pelletizing process, and the operator takes samples from the manufacturing equipment using a sampler at intervals during the granulation process and inspects the results outside the process equipment using a microscope or camera. The small amount of particles taken are measured manually and, in some cases, analyzed using system software. The method then proceeds depending on this inspection. Because the growth process of the generated granular particles proceeds very rapidly, it is often not possible to take and analyze samples quickly enough, resulting in disordered particle growth and failure to achieve the desired product characteristics. Another limitation of the inspection method associated with this process is that it depends on the operator's experience and the number of analyzable particles per sample taken is relatively small. [Prior art documents] [Patent Documents]

[0006] [Patent Document 1] German Patent Application Publication No. 10061085 [Patent Document 2] International Publication No. 2019 / 091507 [Overview of the project] [Problems that the invention aims to solve]

[0007] The fundamental problem of this invention is to provide measures that enable rapid analysis of the granulation process, thereby ensuring that granules can be reliably and reproducibly manufactured with high product quality. [Means for solving the problem]

[0008] This problem is solved in a granulation apparatus by positioning the image acquisition unit within the granulation machine area so that, in relation to the features mentioned at the beginning, the image acquisition unit can capture images of the process chamber during the granulation process, and consequently, capture in-line images of the granules undergoing the granulation process within the process chamber.

[0009] This challenge can be further addressed by the granulation method described at the beginning, which involves capturing images as inline images during the ongoing granulation process in the process chamber, where the granules are growing.

[0010] According to the present invention, there is a favorable possibility of monitoring the granulation process in line in a granulation apparatus, that is, directly monitoring the granular particles growing in size during the ongoing granulation process while inspecting them within the process chamber. A granulation method can be implemented in which images are captured as inline images during the ongoing granulation process within the process chamber. This allows for extremely rapid response to the current process progress, and, for example, to extremely rapid particle growth. Since evaluation can be performed while inspecting a large number of particles, unlike in the case of sampling which is only done occasionally, the achievable analytical results become significantly more accurate and representative. Thus, extremely good and stable product quality is achieved, combined with only minor defects. Analysis is performed based on optical data provided by the imaging unit. The imaging unit is positioned in the granulation process area so as to enable two-dimensional (2D) imaging of the inside of the process chamber and, consequently, of the granules currently undergoing the granulation process within the process chamber, while the granulation process is in progress. The granulation process can proceed without interruption during this so-called inline imaging. The image acquisition unit may be located, for example, within the process chamber, or outside the process chamber, with the possibility of penetrating the structure of the process vessel to image the interior of the process chamber. During the implementation of the method, granular particles currently undergoing the granulation process within the process chamber are directly photographed, and the subsequent granulation process is influenced by changing variable operating parameters of the current granulation process based on the image, in accordance with the subsequent evaluation of the image. The means according to the present invention have been found to be advantageous for monitoring and closed-loop control of granulation processes, particularly those involving extremely rapid particle growth, based on possible real-time image acquisition, because optical in-line evaluation allows for influence on the method with extremely short reaction times. In particular, using in-line image acquisition, which is used to create a sequence of images consisting of multiple images taken directly and in succession, the granulation process is monitored in various ways based on optically detectable manufacturing parameters, such as particle size, particle size distribution, roundness, or other morphological features.Preferably, the granulation apparatus is configured such that imaging of granular particles is possible in a regular, particularly freely pre-selectable, and preferably in a series of images adapted to the production speed. The types of variable operating parameters that may be involved in and affect the operating state of the granulation process depend on the structure and equipment of the granulation machine and relate to, for example, temperature, volumetric flow rate, and / or operating period.

[0011] Although the plural form is used above and below with respect to operating parameters, in simple device structures and simple processes, a variable operating parameter may include only one variable operating parameter. References to variable operating parameters can be understood as references to one or more variable operating parameters.

[0012] Advantageous improvements to the present invention are described in the dependent claims.

[0013] The granulator used in the present invention may, in principle, be based on any functional principle. A configuration of the granulator as a fluidizing granulator is considered advantageous. In this fluidizing granulator, a process gas is used to induce fluidization of the granules during the granulation process. Particularly suitable in this regard is a configuration as a fluidized bed granulator that performs spray granulation, spray agglomeration, spray coating, or spray encapsulation. In a fluidized bed granulator, the process gas contributes to vortexing the granules inside the process vessel, forming a so-called fluidized bed. For special requirements, jet bed technology can be used.

[0014] The configuration of a fluidized bed granulator as a rotor fluidized bed granulator is considered particularly advantageous. The rotor fluidized bed granulator is equipped with a rotor that has a rotor plate for purpose, which can be rotated by a motor. This structural form of the granulator makes it possible to produce granules with particularly high quality values ​​in terms of circularity and surface. The rotating rotor plate transports the granules outward into the process gas flow, which then carries the granules, forming a particularly toroidal fluidized bed.

[0015] The rotor fluidized bed granulator described above is one possible embodiment of a granulator available within the framework of the present invention, which can generally be called a rotor granulator. In another embodiment of the rotor granulator, which is equally advantageous within the framework of the present invention, a process gas, particularly air, guided alongside the rotor through a process vessel is used primarily or exclusively as a shut-off gas, while the actual granulation is caused by granular particles being moved through the process chamber by a rotating rotor, while being continuously mixed, particularly in an annular granular flow, in relation to a vane-like structure disposed in the rotor and / or process vessel. Granular particles with high circularity are produced when the granules are rolled on the surfaces of the process vessel and rotor, including the vane-like structure.

[0016] The granulation machine may be configured, for example, for so-called high-shear granulation. High-shear granulation is a shaping method for granulation in which powdered particles are supplied with a binder liquid in a closed process vessel in which a mixing tool and a chopper are located. Since the mixing tool includes a motor-driven rotor for practical purposes, this granulation machine may also be called a rotor granulator. High-density granules are formed through the resulting liquid and solid crosslinks.

[0017] In a preferred configuration of the granulation apparatus, the residence period of granular particles in the ongoing granulation process, also referred to hereafter as the processing period, is defined as a variable operating parameter. In a granulation apparatus configured for batch operation, the processing period can be set, for example, by switching the granulation process on and off. In a continuous granulation process, the processing period arises, in particular, based on the time difference between the loading of the starting material into the ongoing granulation process and the removal of granular particles from the ongoing granulation process. When the method is implemented, the processing period can be set, for example, by an electronic control device present for evaluating two-dimensional images from an imaging unit.

[0018] The process chamber of the granulation equipment's process vessel is connected to a process gas inlet configured to supply a process gas that is appropriately temperature-controlled for its purpose, and further to a process gas outlet that works to discharge the supplied process gas. The process gas is, for example, heated air or heated inert gas. The process gas causes, for example, drying of the material in the process chamber, thereby causing granulation by, for example, spray granulation or spray agglomeration. Additionally or alternatively, the process gas can be used, in particular in a rotor granulator, as a shut-off gas to prevent granular particles from falling downward between the rotating rotor and the vessel wall of the process vessel. The volumetric flow rate and / or temperature of the process gas can be used as variable operating parameters that can be changed by an electronic control device, which is advantageous as it allows the operating state of the granulation process to be influenced, in particular, depending on the evaluation of captured images.

[0019] To enable spray granulation, the granulator is equipped with a spray nozzle assembly for the purpose. The spray nozzle assembly allows the spraying of the granulation liquid into the process chamber of the process vessel. This makes it possible to spray a solid-containing liquid, such as a solution, suspension, or molten liquid, into the process chamber when carrying out the method according to the present invention. In the process chamber, the liquid component evaporates based on high heat exchange with the process gas, and the remaining solid forms small particles as carrier nuclei. These carrier nuclei are wetted with another liquid, and after further evaporation, a hard coating is formed around the carrier nuclei. This process is continuously repeated, so that the growth of granular particles occurs layer by layer. In an alternatively possible spray agglomeration, very small particles existing in powder form are moved in a fluidized bed induced by the process gas, and a binder liquid is sprayed from a spray nozzle assembly. Here, the particles bond together based on the formation of liquid crosslinks to form agglomerated granular particles. In this case, the spraying process is continued until the desired size of the granular particles existing as aggregates is achieved.

[0020] Variable operating parameters of the granulation process when a spray nozzle assembly is present include, in particular, the volumetric flow rate of the granulation liquid supplied into the process chamber and / or the spray duration and / or droplet size.

[0021] The granulator is preferably equipped with a feeder, which provides carrier nuclei, particularly in powder form, into the process chamber, forming the basis for granulation. In this method, the granulation liquid, which is then sprayed, acts merely as a transport element to bring the solid to be deposited in layers. In this case, the variable operating parameter of the granulation process may be the amount of carrier nuclei that can be supplied into the process chamber.

[0022] If the granulation machine has a rotor that can be driven by a motor, the variable operating parameter of the granulation process may be the rotational speed of the rotor, which can be set by correspondingly controlling the operation of an assigned electric drive motor.

[0023] Capturing images of granules by an image capturing unit can be performed, depending on the structure of the granulation apparatus, using an image capturing unit disposed directly in a process chamber, or using an image capturing unit disposed outside the process chamber. From the viewpoint of safety, particularly explosion protection, an image capturing unit disposed in the outer region of the process vessel is generally preferred. In this case, the vessel wall of the process vessel expediently has at least one transparent wall section. In the region of this transparent wall section, the image capturing unit is arranged outside the process chamber such that the image capturing unit can capture images of the process chamber through the transparent wall section, and thus capture in-line images of granules present in the process chamber. When carrying out the granulation method according to the present invention based on this, the in-line images of the granules in the process chamber are captured from outside the process chamber through the transparent wall section of the vessel wall of the process vessel.

[0024] Since the transparent wall section is in particular a limited area of the vessel wall surrounded by the opaque wall section of the vessel wall, the transparent wall section defines a transparent observation window. This observation window is preferably made of transparent glass or plastic.

[0025] Alternatively, for example, a structure of the process vessel is possible in which the vessel wall is at least predominantly, preferably entirely made of a transparent material, for example a correspondingly highly transparent plastic, in which case the transparent wall section used for image capturing is a partial area of a large-area transparent vessel wall.

[0026] The image capturing unit disposed outside the process chamber, thus outside, may be attached to an independent support structure depending on the process vessel, but is preferably directly attached to the process vessel on the outside. For this purpose, it is expedient if the process vessel has, on the vessel wall on the outside, a mounting interface, also referred to as a vessel-side mounting interface, said vessel-side mounting interface being adapted to the structure of the image capturing unit, and the image capturing unit being attached to this vessel-side mounting interface in the use position for carrying out the method. Preferably, the vessel-side mounting interface is configured for screw fastening of the image capturing unit, so that simple and quick removal of the image capturing unit from the process vessel is possible for maintenance purposes or for other reasons.

[0027] For particularly detachable assembly on a process vessel, the image capturing unit is expediently provided with a mounting interface, which is also referred to as an image capturing unit-side mounting interface for the sake of clear distinction. The image capturing unit-side mounting interface is functionally adapted to any of the above-described vessel-side mounting interfaces.

[0028] The image capturing unit is expediently equipped with an electromechanical connecting device. Via this electromechanical connecting device, an electrical connection can be established to an electronic control device that sets one or more variable operating parameters of the granulation process. The electromechanical connecting device expediently comprises a plug-in coupling device for at least one electrical cable, or comprises at least one electrical cable itself that extends directly therefrom.

[0029] In particular, an internet connection to the electronic control device is established via the electromechanical connecting device. This internet connection enables data exchange between the two components, and the voltage supply that provides the required operating voltage is also expediently carried out via this electromechanical connecting device.

[0030] The electronic control device is expediently a component of the granulation apparatus.

[0031] The image acquisition unit is preferably equipped with an optoelectronic structure. This optoelectronic structure includes an image sensor and an objective lens positioned in front of the image sensor toward the image to be captured. The image sensor is, for the purposes of its purpose, a component of a sensor unit integrated into the optoelectronic structure, which, in addition to the image sensor, has yet another component of an electronic and / or mechanical kind. The sensor unit and the objective lens together form a camera. This camera is particularly a color camera, but may be configured as a monochrome camera.

[0032] The objective lens is preferably a telecentric objective lens, which conveniently has a fixed focal length. This offers the advantage that, when the image area is in focus, the grain size is fixedly defined, and unlike wide-angle objective lenses, the difference between small, nearby grains and large, distant grains can be clearly observed. Compared to telecentric objective lenses with variable focal lengths, which are equally usable in principle but require changes in the focal plane to be brought about by modifications in the objective lens, telecentric objective lenses with fixed focal lengths allow for significantly simpler adjustment and evaluation, while eliminating cumbersome conversion and calibration measures. Image evaluation does not require particularly complex conversions, as the captured pixels always correspond to exactly one unit of length, depending on the design of the objective lens. Telecentric objective lenses are particularly bi-telecentric in structure.

[0033] A telecentric objective lens, which has a fixed focal length for practical purposes, results in a relatively small depth of field. This relatively small depth of field is, for example, in the range of only 1.1 mm. Correspondingly, precise positioning of the focal plane, defined by the optical components, is necessary. This focal plane defines the image acquisition plane with optimal image sharpness. To allow for the highest possible flexibility for adjustment measures, it is advantageous for the image acquisition unit to have an electrically operable linear module supporting the optoelectronic components. The linear module allows for stepless linear movement of the optoelectronic components for changing and adjusting the position of the focal plane, also called the plane of focus. For practical purposes, there is a fixed distance between the objective lens and the image sensor. This distance does not change when the position of the optoelectronic components is changed. Therefore, calibration is not necessary even when changing the focal plane; it is solely important to position the optoelectronic components so that the granular particles to be imaged are located in the working area or at the focal plane of the objective lens.

[0034] Instead of an electrically operable linear module, the image acquisition unit may alternatively include positioning devices of different structural types for positioning the optoelectronic structures, for example, a manually operated device with a tightening screw for release and locking at any desired position.

[0035] To record clear images, it is advantageous that the image acquisition unit has an illumination device that can illuminate the area to be imaged, i.e., at least the focal plane of the optoelectronic structures. The illumination device is preferably configured using LED technology. When the method is implemented, the illumination device may be used in pulsed operation adapted to the frequency of image acquisition, or it may be used in continuous operation. Continuous operation is technically easier to implement because the captured image does not need to be matched to the bright stage of the flashlight in relation to the exposure time. With regard to explosion protection, there is also an advantage based on the fact that ignition sparks are avoided in continuous light.

[0036] As an illumination means, the illumination device preferably includes annular illuminators arranged coaxially with respect to the optical axis of a group of optoelectronic structures. This allows granular particles moving through the focal plane to be photographed accurately and precisely without forming interfering shadows. The illumination of the focal plane is extremely homogeneous.

[0037] The granulation apparatus, for practical purposes, includes the electronic control device already described above, which evaluates the two-dimensional image of the granules created in the process chamber during the granulation process and, depending on the evaluation results, sets the variable operating parameters of the granulation process or the granulation apparatus to have a desired effect on the operating state and, consequently, the process conditions. In particular, using the electromechanical connection device already described above, the image data of the captured image can be transmitted from an electrically operated image acquisition unit to the electronic control unit.

[0038] Preferably, bidirectional signal transmission is possible between the image acquisition unit and the electronic control unit, and this bidirectional signal transmission can be used not only for image evaluation but also for electrical operation control of the image acquisition unit, including the transmission of electronic image acquisition commands that trigger the acquisition of desired images. This is done purposefully by cable connection and via corresponding electrical communication lines, but can also be done without cables, particularly by wireless transmission.

[0039] The electronic control device includes, for the purpose of purposes, an electronic data processing device. This electronic data processing device is configured for image processing of images captured by an image acquisition unit, and this image processing is performed when the method according to the present invention is implemented. The electronic data processing device can, in particular, perform calculations of granule-related result values ​​based on the acquired image data, which are hereafter simply referred to as result values ​​for simplicity, and are one or more parameters from the group of the average particle diameter of the granule particles, the particle size distribution of the granule particles, and the median particle diameter. Based on the particle size distribution, a growth curve of particle growth can be generated while considering a series of images. Based on this growth curve, the temporal progression of particle growth can be read. Overall, the granule-related result values ​​reflect the current actual state of granule particle quality in the ongoing granulation process.

[0040] An electronic data processing device can, for the purposes of its purpose, perform image processing such that the calculation of granule-related result values ​​is based at least substantially only on granules located at the focal plane of the image processing unit. This ensures that the granules considered are based on the same reading or measurement scale, and therefore the calculated result values ​​do not have significant distortion, especially when using a telecentric objective lens. For good distinction, granules located at the focal plane are referred to as reference granules. In this case, only granules identified as reference granules are considered when calculating granule-related result values. Preferably, particle size is considered, and the particle size, particularly the particle diameter, can be estimated based on the electronically measured particle circumference.

[0041] The electronic control unit is, for the purpose, equipped with an electronic operating state control device. This operating state control device communicates with an electronic data processing device and is provided to adjust variable operating parameters that affect the operating state of the granulation process based on pre-determined granule-related result values. To this end, the operating state control device outputs a signal, also called an operating signal, corresponding to the desired operating parameter to the device component of the granulator responsible for that operating parameter. Depending on the equipment, the operating signal can be output to, for example, a liquid pump that sprays the granulation liquid, a pumping unit of the carrier nucleus feeder, a drive motor of the rotor fluidized bed granulator, and / or a blower that supplies process gas, and is transmitted by the operating state control device to, for example, one or more of these device components when the method according to the present invention is implemented.

[0042] The electronic operating condition control device may be a separate component from the electronic control device, or it may be an integrated component of the electronic data processing device.

[0043] Preferably, the electronic control device is configured such that it can perform closed-loop control to generate adjustment signals, particularly in a closed-loop control circuit. To this end, the electronic control device is equipped with a closed-loop control device. In this closed-loop control device, a comparison is made between granule-related result values ​​calculated based on a two-dimensional image and pre-stored target values, and as a result of this comparison, an adjustment signal for an electronic operating state control device is generated. For the purpose of this, in the closed-loop control device, the granule-related result values ​​function as a controlled variable, and this controlled variable is compared with a pre-stored target value stored as a target variable. The operating state control device can interpret the obtained adjustment signal and output an operating signal as an operating variable to the device components based on this signal.

[0044] For practical purposes, an electronic control device is equipped with an input device. This input device allows input of target values, in particular, for internal storage within the electronic data processing device. The input device includes, for example, a keyboard and / or an interface for electronic input devices.

[0045] The electronic control device has an electronic output device which can output granule-related result values ​​calculated by an electronic data processing device, and is even more advantageous if it is output when the method according to the present invention is implemented. The output device can further be configured and used to output other process-related information, for example, information regarding the current operating conditions in the granulator, such as the temperature of the process gas or the amount of granulation liquid being sprayed. Particularly effective monitoring is possible if the output device includes a display device that visualizes the information to be output. Such a display device may be, for example, a monitor which may display electronically usable information in the form of alphanumeric characters and / or curves and / or diagrams. For example, the average size, average particle size distribution and / or morphology of photographed granule particles may be displayed or selected to be displayed as a continuous curve over process time with freely configurable subdivisions.

[0046] For particularly smooth and precise operation of the granulator, the electronic control unit, preferably configured as a component of the granulator, is equipped with artificial intelligence (AI), which is for purpose only referred to as "AI" below. For particularly effective image processing, an AI having a convolutional neural network is preferably used. The AI ​​can interpret images consisting of multiple 2D images from an image acquisition unit and identify the aforementioned reference granule particles used when calculating granule-related result values. By training the AI, particle identification can be achieved with high accuracy. This training is performed particularly manually by providing the AI ​​with images in which reference granule particles have been manually marked in advance, especially while using the aforementioned input device.

[0047] Artificial intelligence (AI) is equipped with, for its purpose, data processing components, learning algorithms, decision components, output components, and interaction components. The data processing components are particularly responsible for the data processing necessary for training the AI, such as manually defining reference granules as described above. The learning algorithms are responsible for training the AI ​​and include algorithms for machine learning, such as decision trees or artificial neural networks, especially at least one convolutional neural network. The decision components work for the AI's decision-making, performing a closed-loop control process, so to speak. These decision components analyze usable data, particularly granule-related result values ​​and target values, and make decisions in line with the objective. Decision components include, for example, decision rules or heuristic approaches. Output components work for the aforementioned output of results or other information, such as generating graphics, diagrams or tables, or simply text. Output components can also work, for example, for controlling output devices. Interaction components are those through which the AI ​​interacts with its environment, such as components configured as electrical interfaces. Through this electrical interface, the output of input signals for operating condition control devices is performed.

[0048] The granulation method according to the present invention can be carried out using any granulation apparatus adapted to the method, but it is preferably carried out using the granulation apparatus according to the present invention.

[0049] During the granulation method according to the present invention, inline images of the granules in the process chamber are created, for the purpose of being taken from outside the process chamber, through a transparent wall section of the process container wall. This allows the process chamber to be used for the granulation process without interference caused by process monitoring, and the image acquisition unit does not come into contact with the granules during production.

[0050] For the purpose of the granulation process, an electronic control device is used to process images captured by an image acquisition unit during the granulation process. Through image processing, granule-related result values ​​are calculated, particularly the average particle diameter and / or particle size distribution and / or median granule diameter of the granule particles. Based on these granule-specific result values, an adjustment signal is generated, and this adjustment signal is used to set variable operating parameters that affect the operating state of the granulation process.

[0051] During the granulation process, it is advantageous to generate adjustment signals using closed-loop control, where this closed-loop control is based on a comparison between granule-related result values ​​and set target values. This is performed in a closed-loop control circuit, preferably using an appropriate electronic closed-loop control device.

[0052] Preferably, during the granulation process, in order to calculate granule-related result values, only the granule particles located at the focal plane of the image acquisition unit (42) among the granule particles visible in the captured image are identified as reference granule particles, and only these identified reference granule particles are used as the basis for calculating granule-related result values. For this purpose, image processing is preferably performed to electronically measure the particle size of the reference granule particles, particularly the circumference of the reference granule particles. The image processing is preferably performed using an electronic data processing device.

[0053] The granulation method is preferably carried out using a granulation apparatus, as described above. This granulation method is particularly a granulation method for producing granules consisting of a large number of granular particles, wherein a granulation process involving particle growth is carried out in a process chamber defined by the container wall of a process vessel, the granulation process is monitored using an electrically controllable image capture unit, a two-dimensional image of the granules is captured by the image capture unit, this image is then evaluated using an electronic control device, and the evaluation of the image is used to set variable operating parameters that affect the operating state of the granulation process, the image is created as an inline image during the granulation process in which the granules are growing in the process chamber, the granulation method is carried out using a granulation apparatus, and the granulation apparatus has a granulation machine. The granulation machine has a process container with a container wall surrounding a process chamber, and performs a granulation process to produce granules consisting of a large number of granular particles within the process container. The operating state of the granulation process is influenced by operating parameters, and the granulation machine also has an electrically controllable image capture unit. The two-dimensional images of the granules captured by the image capture unit are evaluated for purposes by an electronic control device also belonging to the granulation machine, and the image capture unit is positioned within the area of ​​the granulation machine so that it can capture images of the process chamber during the granulation process, and consequently, capture in-line images of the granules undergoing the granulation process within the process chamber.

[0054] The present invention will be described in more detail below with reference to the accompanying drawings. [Brief explanation of the drawing]

[0055] [Figure 1] This is a schematic diagram showing a preferred embodiment of the granulation apparatus according to the present invention, while the granulation process is progressing and a preferred granulation method according to the present invention is being carried out. The granules inside the process container are shown in a partially enlarged view surrounded by a dashed line. [Figure 2]Figure 1 shows an enlarged view of the portion X enclosed by a dashed line, where a preferred embodiment of the image acquisition unit is shown in a longitudinal cross-section along the cutting line II-II shown in Figure 4, at the usage position of the image acquisition unit assembled on the outside of the process vessel. [Figure 3] Figure 2 is a top view of the assembly shown in Figure 2, viewed from above in the line of sight indicated by arrow III, where the housing of the image acquisition unit, which surrounds the important components of the image acquisition unit, is simply indicated by a dashed line. [Figure 4] Figure 2 is an axial front view showing the image acquisition unit in the line of sight indicated by arrow IV. [Figure 5] This diagram relates to the granulation method. Part (b) shows a diagram displayed by the output device, which is a histogram plotting the number of granular particles "A" to be analyzed over the particle diameter "D," while part (a) shows an image of the granules created by the image acquisition unit. Based on this image, the diagram shown in part (b) is generated. [Modes for carrying out the invention]

[0056] Figure 1 shows a schematic representation of the granulation apparatus 1, which will be described in more detail below. This granulation apparatus 1 has a favorable structure, and the granulation process is carried out using this granulation apparatus 1. The granulation apparatus 1 can be operated to carry out the granulation process using the granulation method, which will also be described in more detail below.

[0057] The granulation apparatus 1 includes a granulation machine 2 having, for example, a box-shaped or drum-shaped process container 3, and the process container 3 has a container wall 5 surrounding an inner chamber called a process chamber 4.

[0058] The process vessel 3 has a bottom surface 6 that is oriented vertically downward and a top surface 7 that is oriented vertically upward in the opposite direction to the bottom surface 6. The height direction 8a of the process vessel 3, defined by the axial direction of the height axis 8, is indicated by a dashed line. In the normal operating position of the process vessel 3, the height axis 8 extends vertically.

[0059] An exemplary granulator 2 is a fluidizing granulator. This fluidizing granulator has the characteristic of making the granules 11 currently undergoing the granulation process into a fluid, fluid state. Preferably, the granulator 2 is a fluidized bed granulator 2a. In a fluidized bed granulator 2a, the granules 11 in the process chamber 4 are raised and vortexed by the process gas supplied according to the flow arrow 14 during the granulation process, so that a fluidized bed 15 is generated in the process chamber 4. The fluidized bed state is maintained as long as the process gas is supplied into the process chamber 4.

[0060] Within the fluidized bed 15, individual granular particles 12 of the granules 11, which exist in various sizes, are mixed together and swirling, behaving like a fluid.

[0061] Using the granulation apparatus 1, a granulation method can be carried out in which granules 11 consisting of a large number of granular particles 12 are produced by corresponding operation. The material composition of the granular particles 12 is tailored to the intended use, for example, in the composting field or especially in the pharmaceutical field. The produced granules 11 are used, for example, to manufacture compost pellets or medically usable tablets.

[0062] In particular, the removal device 16 located in the lower surface 6 region of the process container 3 has a removal opening 16a suitable for opening as needed, allowing the manufactured granules 11 to be removed for continued use. For example, a tablet press may be connected to the removal device 16.

[0063] The granulator 2 includes a process gas inlet 17 located in the process container 3, through which the aforementioned process gas can be supplied into the process chamber 4, particularly from below, according to the flow arrow 14. The process gas is, for example, an inert gas, and preferably air. A motor-driven blower 18, positioned in front of the process gas inlet 17, supplies process gas to the process gas inlet 17 and, consequently, to the process chamber 4, at a desired volumetric flow rate and gas pressure.

[0064] The process gas supplied for the granulation process is purposefully temperature-controlled and heated to a particularly appropriate temperature. This allows the process gas to supply the thermal energy required for the granulation process into the process chamber 4. For example, the process gas inlet 17 is equipped with a heat source 21, which is, for example, a gas heater designed as a heat exchanger. However, the heat source 21 for heating the process gas may be located elsewhere, in particular upstream of the blower 18.

[0065] Furthermore, the process chamber 4 is connected to a process gas outlet 22, particularly in the area of ​​the upper surface 7 of the container. The process gas outlet 22 serves to expel the process gas supplied through the process gas inlet 17. As the process gas flows through the process chamber 4, it transfers the thermal energy required for the particle-based process to the granules 11 or the starting material for the granules 11.

[0066] Preferably, the granulator 2 is a rotor granulator 2b corresponding to the illustrated embodiment. In this case, the granulator 2 has a rotor 23a located in the process chamber 4, corresponding to the illustrated embodiment, which is rotatable by a motor about a rotation axis 20 extending in the height direction 8a, and is equipped with a rotor plate 23. An electrically operated drive motor 24 is present to cause the rotational motion of the rotor 23a, which is mounted on the outside of the process vessel 3, particularly in the area of ​​the lower surface 6 of the vessel. The rotor plate 23 extends in a plane perpendicular to the height axis 8, i.e., oriented horizontally as an example. The rotor plate 23 is located in the lower chamber region 4a of the process chamber 4, which is allocated to the lower surface 6 of the vessel.

[0067] The container wall 5 has, for example, a side wall 25 formed in the shape of a hollow cylinder. This side wall 25 extends to surround the height axis 8 and laterally encloses the process chamber 4 in an annular shape. An annular gap 26, shown in enlarged detail in the drawing, is formed between the outer edge of the rotor plate 23 of the rotor 23a and the side wall 25. Through this annular gap 26, process gas supplied via the process gas inlet 17 located below the rotor plate 23 can flow upward.

[0068] Exemplary, the rotor granulator 2b is a fluidized bed granulator 2a formed as a rotor fluidized bed granulator, in which process gas flowing upward through an annular gap 26 interacts with granular particles 12 to form a fluidized bed 15 in the upper chamber region 4b of the process chamber 4, located above the rotor plate 23.

[0069] According to one embodiment (not shown) of a fluidized bed granulator 2a usable for the present invention, the rotor 23a is omitted, and instead of the rotor, a stationary sieve-like structure is provided. A process gas that interacts with the granular particles 12 on the sieve-like structure is passed from below through this sieve-like structure.

[0070] In another advantageous embodiment of the rotor granulator 2b, a process gas guided through the process chamber 4 and alongside the rotor plate 23 according to the flow arrow 14 is used as a barrier gas. The barrier gas prevents the granular particles 12 from falling through the annular gap 25 into the area below the rotor plate 23, particularly like a kind of gas curtain. Air is particularly used as the process gas. Actual granulation is caused by the granular particles 12 being moved through the process chamber 4 while being continuously mixed, particularly in an annular granular flow, in relation to a vane-like structure 9, indicated by a dashed line in Figure 1, which is fixedly positioned on the rotor plate 23 above and / or on the vessel wall 5 of the process vessel 3 inside, by the rotating rotor 23a. In particular, granular particles 12 with high circularity are produced when the granular particles 11 are rolling on the surfaces of the process vessel 3 and the rotor 23a, including the vane-like structure 9.

[0071] Granulator 1 is configured, exemplary, to carry out a granulation process also known as spray granulation. In spray granulation, the granulation liquid supplied to the liquid tank 27 of granulator 1 is sprayed into the process chamber 4 via a spray nozzle assembly 28 located in the process chamber 4, as shown by the dotted line 31. The spray nozzle assembly 28 is connected to the liquid tank 27 via a motor-driven liquid pump 32 of granulator 1b. While the liquid pump 32 is running, the granulation liquid is drawn in from the liquid tank 27, finely distributed and sprayed into the process chamber 4, while being mixed with air to form a particularly fine spray mist.

[0072] The granulation apparatus 1 can perform spray granulation, in which granules 11 are formed exclusively from a sprayed granulation liquid. In this case, a solid-containing granulation liquid, such as a suspension, is sprayed into the process chamber 4. The aqueous component evaporates, and the remaining solid acts as a carrier nucleus. This carrier nucleus is then moistened by the continuously supplied granulation liquid. From this granulation liquid, a hard coating is formed that surrounds each carrier nucleus after further evaporation. In this continuously repeated granulation process, granular particles 12 having an onion-like layered structure are produced.

[0073] Preferably, the granulator 1 provides the possibility of supplying a predetermined amount of suitable carrier nuclei into the process chamber 4 at the start of the granulation process. In this case, the supplied granulation liquid is not used for nucleation but simply for layered particle growth. For example, the granulator 1 is equipped with a suitable feeding device 33, which can be used to supply carrier nuclei into the process chamber 4. The feeding device 33 includes, for example, a motor-driven pumping unit 34, configured as a screw conveyor, and a carrier nucleus storage container 35 connected to the pumping unit 34, which is filled with a sufficient amount of carrier nuclei when the granulation process is carried out.

[0074] The granulator 1 can also be used, for its intended purpose, for a granulation process in which granules are formed by spray agglomeration. In spray agglomeration, extremely small, powdery particles present in a consistent state are moved within a fluidized bed by a process gas, and a granulation liquid acting as a binder is sprayed onto these particles from a spray nozzle assembly 28. In this case, numerous particles bond together, forming liquid bridges, to form aggregates. The spraying process continues until the aggregates reach the size desired for granular particles. Powdered particles can be introduced using a feeder 33.

[0075] To obtain granules 11 having the desired morphology, particularly 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 granulator 1 is equipped with an electronic control device 36, as indicated by the dashed line in Figure 1.

[0076] The electronic control device 36 is electrically connected via a control line 37, indicated by a dashed line, to a device component 38 of the granulator 1 whose operating parameters are variable. Such a device component 38 is also called an influential device component 38 for good distinction.

[0077] An electrical operating signal can be supplied via the control line 37 to the device component 38 that can be affected, and this operating signal sets the operating state of the applicable device component 38 that can be affected.

[0078] Exemplary, the granulation apparatus 1 includes a blower 18, a heat source 21, a drive motor 24, a liquid pump 32, and a pressure unit 34 as apparatus components 38 that can be affected. Depending on the configuration, the granulation apparatus 1 may have any sub-combination of these apparatus components 38 that can be affected and / or other apparatus components 38 that can be affected.

[0079] The variable operating parameter may be the volumetric flow rate for the blower 18, and the temperature of the process gas that can be supplied through the process gas inlet for the heat source 21. The variable operating parameter may be the rotational speed of the rotor 23a for the drive motor 24. The variable operating parameter may be the volumetric flow rate and / or spray duration and / or droplet size of the granulation liquid for the liquid pump 32. The variable operating parameter may be, for example, the amount of carrier nuclei that can be supplied into the process chamber 4 for the supply device 33.

[0080] For the purpose of purposes, the residence period of the granular particles 12 in the ongoing granulation process, also referred to hereafter as the processing period, can be influenced by correspondingly controlling the operation of the influencing device components 38. If the granulation process is carried out as a batch process, corresponding to the illustrated embodiment, the processing period can be influenced, for example, by switching off the granulation process, which can be achieved, for example, by stopping the operation of the influencing device components 38. Particularly in this regard, the extraction device 16 can be made motor-operable and connected to an electronic control device 36 via another control line 37 (not shown), thereby the extraction device 16 also forms an influencing device component 38, and the operation of the extraction device 16 can provide the advantage of being able to extract the manufactured granules from the process chamber 4 as needed.

[0081] It is self-evident that the granulation apparatus 1 may be configured to carry out an alternative continuous granulation process. In this case, the manufactured granules are continuously removed from the process chamber 4 when the desired properties are achieved, particularly when the desired particle size is achieved, and replaced with newly manufactured granules, for example, by a continuous supply of carrier nuclei. In this case, the processing period is determined based on the residence period of the granules 12 in the process chamber 4.

[0082] The granulation apparatus 1 is equipped with an electrically controllable image acquisition unit 42. This image acquisition unit 42 can capture two-dimensional images of the process chamber 4 and, by extension, the granules 11 currently undergoing the granulation process within the process chamber 4 during the granulation process. These two-dimensional images can be evaluated by an electronic control device 36, which can then be used to set the operating parameters of the granulation apparatus 1, particularly to change the operating parameters for the purpose of altering the operating state of the granulation process. An electrical communication line 43, indicated by a dashed line, enables the transmission of data necessary for this purpose from the image acquisition unit 42 to the electronic control device 36. For example, the electrical communication line 43 is realized using an electromechanical connector 44 of the image acquisition unit 42. The electromechanical connector 44 has a connector to which a connecting cable leading to the electronic control device 36 can be connected.

[0083] The electrical communication line 43 enables bidirectional data traffic. Therefore, the operation of the electrically controllable image acquisition unit 32, particularly the image acquisition process of the image acquisition unit 42, can be controlled in an open loop by the electronic control device 36. The possibility of open loop control arises particularly with respect to the frequency of image acquisition, the time interval between consecutive image acquisitions, and / or the exposure period.

[0084] The possibility of performing imaging inside process chamber 4 offers the significant advantage of performing inline imaging of granules undergoing the granulation process within process chamber 4, that is, directly during particle growth in the process. This enables at least near real-time monitoring of the process progress, which in turn allows for immediate process intervention to modify the process progress as needed.

[0085] Preferably, automated image acquisition, initiated by the electronic control device 36, is performed continuously throughout the process. In this case, the electronic control device 36 immediately initiates changes to one or more operating parameters if the progress of the process does not conform to a standard. Removing granular particles from the ongoing granulation process to perform analysis is not necessary in the described structure and is not performed in the described manner.

[0086] The image acquisition unit 42 includes an optoelectronic structure group 45. This optoelectronic structure group 45 is configured as a type of camera for practical purposes and defines an optical axis 46. The optoelectronic structure group 45 includes an image sensor 47 and an objective lens 48 positioned in front of the image sensor 47 in the axial direction of the optical axis 46. The image sensor 47 is a component of a sensor unit 49 integrated into the optoelectronic structure group 45, which has further electronic and / or mechanical components in addition to the image sensor 47.

[0087] The optical structure group 45 is assembled to the support structure 51 of the image acquisition unit 42, and via the support structure 51, the image acquisition unit 42 is attached to the granulation machine 2 in the illustrated usage position. The image acquisition unit 42 has a mounting interface called the image acquisition unit side mounting interface 53 on its front surface 52 oriented in the axial direction of the optical axis 46, for good distinction. This image acquisition unit side mounting interface 53 is compatible with another mounting interface called the container side mounting interface 54, located in the process container 3 of the granulation machine 2, in which case the image acquisition unit 42 can be attached to or mounted to the process container 3 externally, particularly in a removable form, while occupying a usage position, through the cooperation of both of these mounting interfaces 53, 54.

[0088] The container-side mounting interface 54 is, exemplary, located on the outer surface 55 of the container wall 5, facing away from the process chamber 4, and preferably located on the side wall 25. The container-side mounting interface 54 exemplary includes a mounting ring 54a, which is welded to the outer surface 54 of the side wall 25. The image acquisition unit-side mounting interface 53 includes a mounting flange 53a, which has a through hole that aligns with a threaded hole in the mounting ring 54a. The mounting flange 53a is a component of the support structure 51. The mounting flange 53a, and thus the support structure 51, and therefore the entire image acquisition unit 42, are attached to the container wall 5 in a removable manner by a number of mounting screws 56 that are inserted into the through hole in the mounting flange 53a and screwed into the threaded hole in the mounting ring 54a. In this case, the optical structure group 45 occupies a position where the optical axis 46 penetrates the container wall 5, exemplary the side wall 25, particularly at a right angle within the mounting area 57 defined by both mounting interfaces 53 and 54 that cooperate in the illustrated embodiment.

[0089] The image acquisition unit 42 has an elongated shape, exemplifyingly having a longitudinal axis 62 that has the same orientation as the optical axis 46.

[0090] The image acquisition unit 42 has a light-entry aperture 58 on its front surface 52 that is aligned with the optical axis 46, and the light-entry aperture 58 is, for the purpose, covered by a light-transmitting and particularly transparent windshield 61. This windshield 61 is made of borosilicate glass in particular. The windshield 61 is preferably fixed in a replaceable manner to the support structure 51 by a retaining ring 63, which is positioned between the mounting ring 54a and the mounting flange 53a in the operating position of the image acquisition unit 42 and is exemplary screw-fastened to the mounting flange 53a. In this case, for the purpose, the windshield 61 is pressed against the outer surface 55 or separated from the outer surface 55 by a minimum distance.

[0091] The objective lens 48 is located between the light-entry aperture 58 and the sensor unit 49, and is spaced apart from the light-entry aperture 58.

[0092] In the region of the container-side mounting interface 54, to which the optical axis 46 extends, the container wall 5 is formed transparently. The container wall 5 has a transparent wall section 64 in this region, which allows for unobstructed viewing of the process chamber 4, and consequently the granules 11 currently inside the process chamber, from outside the process container 3. The light incidence aperture 58 is positioned adjacent to the transparent wall section 64. This allows the imaging unit 42 to perform image acquisition of the process chamber 4, and consequently the granules 11 currently undergoing the granulation process inside the process chamber 4, through the transparent wall section 64. Exemplarily, the transparent wall section 64 is formed by a transparent observation window 64a made of glass or plastic. This observation window 64a is incorporated into the container wall 5, particularly as a porthole, and exemplary into the opaque wall section 65 that forms the rest of the container wall 5. The transparent wall section 64 is formed to be gas-impermeable, like the rest of the container wall 5.

[0093] A focal plane 66, also called a focal plane, is defined by the optoelectronic structure group 45, particularly the objective lens 48. This focal plane 66 is located in the space of the object to be imaged, in this case the granular particles 21, and their points are clearly imaged on the imaging plane defined by the image sensor 47. Preferably, the image acquisition unit 42 is equipped with a positioning device 67. This positioning device 67 enables variable positioning of the focal plane 66, thereby positioning the focal plane 66 in the process chamber 4 so that it is located at a location where it is desirable for the granular particles 12 to be optically detected. Preferably, the focal plane 66 is positioned in the process chamber 4 in the immediate vicinity of the inner surface 68 of the container wall 5, facing away from the outer surface 55, so that the outer granular particles 12 moving alongside the fluidized bed 15 are always clearly imaged.

[0094] The positioning device 67 allows for the overall position adjustment of the optoelectronic structure group 45 while maintaining the relative position between the image sensor 47 and the objective lens 48.

[0095] As a positioning device 67, an electrically operable linear module 71 is provided as an example. This linear module 71 has a stator 71a attached to a support structure 51 and a traveler 71b that is linearly reciprocating while performing a positioning motion 70 indicated by a bidirectional arrow in relation to the stator 71a. An optoelectronic structure 45 is attached to the traveler 71b. The traveler 71b is configured in particular like a carriage. An electric drive motor 72 of the linear module 71, which cooperates with the traveler 71b on the drive side, is connected to an electromechanical connector 44 via an electrical line 69 and thus to an electronic control device 36 via an electrical communication line 43. Thus, via this electronic control device 36, the desired positioning of the focal plane 66 for adjusting the depth of field is possible.

[0096] Preferably, the objective lens 48 is configured as a telecentric objective lens 48a. Preferably, the telecentric objective lens 48a has telecentricity on the object side, and exemplary, there is a bi-telecentric objective lens 48a that has both telecentricity on the object side and telecentricity on the image side.

[0097] The use of the telecentric objective lens 48a is associated with the advantage that a constant imaging scale exists at the focal plane 66, where 1 pixel (px) consistently corresponds to a defined unit of length. This provides a significant advantage during image evaluation based on simple conversions. In other words, the grain size is defined within the focused image region. For example, a simply small depth of field of 1 mm, based on principle, can be easily compensated while maintaining a fixed focal length through positioning via the positioning device 67. No means of calibration or recalibration are required to carry out the granulation process or method.

[0098] The sensor unit 49 is equipped with a global shutter for its intended purpose. This global shutter can close very quickly, thus providing high quality. During the granulation process, the image acquisition unit 42 captures multiple images of the granular particles 12 moving to partially pass through the focal plane 66 at a very high speed over a continuous time period set by the electronic control device 36. This allows for a short exposure time, reducing the occurrence of motion blur to a non-significant level. Power is preferably supplied using PoE (Power over Ethernet) because, unlike USB connections, it allows for significantly longer cable distances. This has proven particularly advantageous when integrating into relatively large granulation equipment.

[0099] The image sensor 47 is, for example, a CCD sensor or a sensor based on CMOS technology. The pixel size is, for example, 4.5 μm, and based on this, a good relationship is established between the pixel size or sensor resolution and the light sensitivity.

[0100] In this embodiment, the telecentric objective lens 48a used has a magnification of 0.735 and a depth of field of approximately 1.1 mm. Based on this, an effective pixel size of approximately 6.12 μm per pixel is obtained. However, in principle, other objective lens parameters are also possible, for example, a magnification of 1.0 associated with a depth of field of approximately 0.6 mm and an effective pixel size of approximately 4.5 μm per pixel resulting from this is possible. However, based on a smaller aperture cross-section, the latter objective lens supplies less light to the image sensor 47.

[0101] For the optimized positioning of the optoelectronic structure group 45, the image acquisition unit 42 is, for the purpose, equipped with at least one position sensor 73. This position sensor 73 is exemplary mounted on the stator 71a and responds to the traveler 71b. The position sensor 73, which may be, for example, a limit switch, is, for the purpose, connected to the electronic control unit 36 ​​via an electrical communication line 43.

[0102] The positioning device 67 and, more exemplary, the optoelectronic structures 45 on the traveler 71b of the positioning device 67 are mounted via a purposefully appropriate mounting adapter 74.

[0103] The functionally important components of the image acquisition unit 42 are, for the purposes of their purpose, housed within the housing 75 of the image acquisition unit 42, and are, for the purposes of their purpose, covered and thus shielded from the surroundings by this housing 75. The housing 75 is, exemplary, fixed in position on the support structure 51 and is structured, for example, in a tubular shape. Alternatively, the housing 75 may be a direct component of the support structure 51.

[0104] The image acquisition unit 42 is equipped with an illumination device 76 for practical purposes. This illumination device 76 enables illumination of the area to be photographed, particularly the focal plane 66, thereby achieving high-value image acquisition. Exemplaryly, the illumination device 76 includes an annular illuminator 76a arranged coaxially with respect to the optical axis 46. This annular illuminator 76a is preferably located in the area of ​​the light incident aperture 58, and in this area, particularly just behind the optionally selected windshield 71.

[0105] The annular illuminator 76a illuminates the focal plane 66 uniformly. The annular illuminator 76a has a central through-aperture. Image information to be captured can pass through this through-aperture.

[0106] It is advantageous if the through-aperture at the center of the annular illuminator 76a is larger than the diameter of the objective lens. This allows the annular illuminator 76a to be shifted backward by 20mm to 50mm, especially for homogeneous illumination. The sensor unit 49 and objective lens 48 can be shifted further forward by about 20mm toward the front 52, so that the focal plane 66 has a greater gap from the front 52 of the image acquisition unit 42 and is located within the process chamber 4, even when the glass thickness of the observation window 64a is large.

[0107] Preferably, the annular illuminator 76a is housed at least partially by a cooling body 77 surrounding the annular illuminator 76a. This cooling body 77 works for optimal heat dissipation. This allows the annular illuminator 76a to be used with high light intensity.

[0108] Basically, it is advantageous if the lighting device 76 is implemented using LED technology; for example, the annular illuminator 76a is an LED annular illuminator.

[0109] An electronic control device 36, which is suitable for at least fully automated operation and is hereafter simply referred to as control device 36 for simplicity, has a particularly advantageous structure in the illustrated embodiment, which will be described in detail below.

[0110] The control device 36 includes an electronic data processing device 78. This electronic data processing device 78 is configured to process images captured by the image acquisition unit 42. Furthermore, the data processing device 78 is configured to operate the image acquisition unit 42 and, in this case, in particular preferably, to direct the acquisition of desired images in the form of a sequence of images having a plurality of images that are directly consecutive in time.

[0111] The data processing device 78 also communicates with the electronic operating state control device 81, which belongs to the control device 36. The operating state control device 81 itself is connected to the device components 38 of the granulation apparatus 1 that can be influenced, via the signal line 37 described above. Via the signal line 37, the operating state control device transmits an electrical operating signal to the device components 38 that can be influenced. The operating signal is generated in the operating state control device 81 based on the electronic adjustment signal supplied to the operating state control device 81 by the data processing device 78 according to arrow 81a.

[0112] The data processing device 78 further communicates with an electronic output device 82. This electronic output device 82 preferably has a display device 82a. This display device 82a is in particular a display and is configured, for example, as a monitor.

[0113] The control device 36 is equipped with an input device 83 for purposeful purposes to be influenced externally. This input device 83 communicates exemplary with a data processing device 78. Through the input device 83, for example, parameterization of the control device 36 is possible, and manual training of artificial intelligence (AI) 84, which is preferably equipped in the electronic control device 36 and merely symbolically suggested, is possible.

[0114] The input device 83 may be configured for remote input using a digital device and / or for manual keyboard input.

[0115] For closed-loop controlled operation in a closed-loop control circuit, the control device 36 has, for the purpose, a schematicly suggested electronic closed-loop control device 85. This closed-loop control device 85 is preferably integrated into an electronic data processing device 78, as well as an artificial intelligence 84.

[0116] During preferred operation of the granulator 1, a granulation method is performed in which an image of the process chamber 4 is captured using an image acquisition unit 42, triggered by a data processing device 78. This is indicated by an arrow labeled reference numeral 86 in Figure 1. The image acquisition is performed inline, that is, while the granulator 2 is operating and the granulation process is underway, through the transparent wall section 64 of the container wall 5. The image acquisition is performed at the focal plane 66, that is, for example, at the boundary layer outside the fluidized granules 11. Each image acquisition is an instantaneous capture of the granular particles 12 moving at high speed in front of the light incident aperture 58.

[0117] Figure 5(a) schematically illustrates image 42a created by the image acquisition unit 42, where the photographed granular particles 12 are reproduced with significant magnification in the bordered area for better understanding. Image 42a includes both granular particles 12 located at the focal plane 66 and granular particles 12 located behind the focal plane 66.

[0118] Images captured by the image acquisition unit 42 are transmitted sequentially over time to the data processing device 78 via the communication line 43 during the granulation process, where electronic image evaluation is performed. Within the framework of this image evaluation, the data processing device 78 calculates granule-related result values ​​of process-specific parameters. Process-specific parameters are, in particular, one or more parameters from a set of parameters including the average particle diameter of the granule particles 12, the particle size distribution of the granule particles 12, and the median particle diameter.

[0119] However, during this evaluation, only the granular particles 12 located at the focal plane 66 in each image 42a are considered as much as possible. These granular particles 12 are called reference granular particles 12a for good distinction, and are additionally marked with dashed outlines in image 42a of Figure 5(a). Since the imaging scale of the reference granular particles 12a located at the focal plane 66 is known based on the optical design of the photoelectron-optical structure group 45 described above, granular measurements can be calculated very easily based on the pixel size to correspond to actual conditions.

[0120] Identifying reference granules 12a for subsequent evaluation is possible, for example, by considering the sharpness of the image. This is because, with the telecentric objective lens 48a used, granules 12 outside the focal plane 66 are imaged significantly less sharply than granules 12 at the focal plane 66. The shape of the photographed granules 12 can also be used as a selection criterion, based on the fact that granules 12 at the focal plane are not obscured and therefore have a uniform and mostly nearly circular contour, while granules 12 behind the focal plane are partially obscured and therefore have a significant discrepancy in their contour lines.

[0121] The selection process described above can be performed particularly quickly and accurately by utilizing artificial intelligence (AI) 84. Crucial to this is the learning of the AI ​​84 to recognize reference granule particles 12a with as few errors as possible. This learning or training is carried out, in particular, by manually marking reference granule particles 12a on images of granules 11 taken during the granulation process or on images input via a correspondingly configured input device 83, using a marking means, such as a computer mouse. As the training period increases, the AI ​​84 can reliably recognize reference granule particles 12a in the actual operation of the granulation process.

[0122] The data processing device 78 can calculate the above-mentioned granule-related result values ​​based on the identified reference granule particles 12a, particularly using AI84. For example, the identified reference granule particles 12a can be measured electronically with respect to their particle size, especially their circumference. For example, the software places a closed contour line around the identified reference granule particles 12a (marked by a dashed contour line in Figure 5(a)) and calculates the particle circumference based on this contour line, taking into account the underlying imaging scale (e.g., an effective pixel size of 6.12 μm per pixel). Based on this value, the particle diameter representing the particle size can be calculated.

[0123] Each granulation process aims to produce granules 11 having specific characteristics or qualities, particularly granules 11 having granule particles 12 with a specific particle diameter "D". Since the granulation process inevitably produces granule particles 12 with different particle diameters "D", the goal is usually to produce granules 11 having granule particles 12 with a predetermined average particle diameter "M", i.e., a median diameter that matches at least the target value. In any case, it is desirable that the granulation method be carried out so that the calculated granule-related results match as closely as possible to one or more set target values.

[0124] The target values ​​are stored or can be stored as comparison values ​​in the data processing device 78. For example, the input device 83 allows input of one or more target values ​​for granule-related result values.

[0125] In a closed-loop control device 85, which may be implemented as a component of the artificial intelligence 84, during the granulation process, a comparison is made between the granule-related result values ​​calculated by the data processing device 78 and pre-stored target values. In this case, depending on the comparison result, the aforementioned electrical input signal is generated and supplied as an input signal to the electronic operating state control device 81 according to arrow 81a. Therefore, within the closed-loop control circuit, the granule-related result values ​​act as controlled variables, the target values ​​act as reference variables, and the adjustment signals act as manipulated variables for adapting variable operating parameters. The operating state control device 81 is designed to generate operating signals based on the obtained adjustment signals and output them to connected, influential device components 38 in the correct assignment, thereby changing the operating parameters to optimize the granule-related result values.

[0126] The output device 82 can, as an example, display at least granule-related result values ​​in correspondence with the preceding calculations of the data processing device 78, which is performed purposefully during the granulation method. Figure 5(b) shows, as an example, a histogram visualization performed by the output device 82. This histogram shows the particle size distribution of granule particles, where the number of granule particles "A" is shown over the particle diameter "D" based on the image 42a available in Figure 5(a). Furthermore, the median "M" of all particle diameters "D" which forms the basis for image evaluation is also shown. The display can be performed separately for each image from the image acquisition unit 42, or as a median based on multiple medians of multiple images taken consecutively. For example, images can be evaluated at regular intervals and combined to form and visualize a growth curve over the process.

[0127] Preferably, the control device 36 has a selector switch that is operated mechanically or by software. This selector switch allows selection of the type of granule-related result values ​​or other process-related information that can currently be output by the output device 82.

[0128] As long as electrical cabling is mentioned in relation to the network of individual device components, alternative transmission systems that do not use cables, particularly wireless-based ones, may also be used.

[0129] A preferred artificial intelligence (AI) 84, also used in the illustrated embodiment, uses a masked R-CNN as its algorithm. A masked R-CNN is a convolutional neural network, or a convolutional neural network with a mask, and is particularly well-suited for image analysis. When used, an image of granular particles 12 to be examined is input, and in response to the evaluation of this image, particle-specific dimensions, i.e., circumference, area and / or diameter, are output. These dimensions are then subsequently processed as a dataset, thereby obtaining, for example, statistical values ​​regarding particle diameter.

[0130] The convolutional network has 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 with probability values. Furthermore, a Region of Interest (ROI) is generated (multiple regions can be combined for this purpose), an evaluation of the probability of object recognition for the recognized object class, and a bounding box (a rectangular frame around the recognized particle contour) and a mask as the marked object region are created. The quantity, diversity, and quality of the training data used to train the neural network are particularly important for the quality of the marked object region or recognized object, i.e., the granular particles. This training data is created manually, in which case the input device 83 is available. The neural network used may be a pre-trained neural network, for example, one that is already available for another analytical purpose, and this pre-trained neural network is then adapted for the purpose to carry out the granulation method by another training means.

[0131] The duration of the granulation process depends on the degree of agreement between the granule-related result values ​​and the target values. As soon as an acceptable agreement is reached, the granulation process is purposefully interrupted or suspended. The necessary verification for this can be performed using a software-based data processing device 78, or alternatively or additionally, by monitoring the display device 82a by the operator.

Claims

1. A granulation apparatus, The system includes a granulation machine (2), which has a process container (3) with a container wall (5) surrounding a process chamber (4), and a granulation process suitable for producing granules (11) consisting of a large number of granular particles (12) can be carried out within the process chamber (4), and the operating state of the granulation process can be influenced by operating parameters. In the granulation apparatus, the granulation apparatus includes an electrically controllable image acquisition unit (42) that captures a two-dimensional image of granules (11) that can be produced by the granulation process, and the two-dimensional image can be evaluated by an electronic control device (36) configured to set variable operating parameters of the granulation process, A granulation apparatus characterized in that the image acquisition unit (42) is positioned in the area of ​​the granulation machine (2) so that the image acquisition unit (42) can capture images of the process chamber (4) and, consequently, capture in-line images of the granules (11) undergoing the granulation process in the process chamber (4) during the granulation process.

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

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

4. The granulation apparatus according to any one of claims 1 to 3, wherein the granulation machine (2) is a rotor granulator (2b), particularly a rotor fluidized bed granulator, equipped with a rotor (23a) that can be rotated by a motor, and the rotor (23a) has a rotor plate (23) which is for the purpose located in the process chamber (4).

5. The granulation apparatus according to any one of claims 1 to 4, characterized in that a variable operating parameter of the granulation process is the residence period of the granular particles (12) in the ongoing granulation process, and the residence period can be set particularly by switching the granulation process on and off.

6. The granulation apparatus according to any one of claims 1 to 5, characterized in that the granulation machine (2) has a process gas inlet (17) configured to supply process gas to the process chamber (4) in the process container (3), and a process gas outlet (22) similarly configured to supply the supplied process gas to the process chamber (4).

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 supplied through the process gas inlet (17).

8. The granulation apparatus according to any one of claims 1 to 7, characterized in that the granulation machine (2) has a spray nozzle assembly (28) configured to spray the 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 spraying period and / or the droplet size.

10. The granulation apparatus according to any one of claims 1 to 9, characterized in that the granulation machine (2) has a supply device (33) for supplying carrier nuclei, which are the basis for granule formation and are particularly in powder form, into the process chamber (4).

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

12. A granulation apparatus according to any one of claims 1 to 11 related to 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), and the image acquisition unit (42) is positioned outside the process chamber (4) in the region of the transparent wall section (64) so ​​that the image acquisition unit (42) can capture images of the process chamber (4) through the transparent wall section (64), and consequently capture images of the granules (11) inside the process chamber (4).

14. The granulation apparatus according to claim 13, characterized in that the transparent wall section (64) of the container wall (5) is a transparent observation window (64a) made of glass, in particular, surrounded by an opaque wall 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 attached to the process container (3) on the outside, and for the purpose a container-side mounting interface (54) adapted to the image acquisition unit (42) is arranged on the container wall (5) of the process container (3) on the outside.

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-side mounting interface (53) configured to fix the image acquisition unit (42) in a fixed position relative to the process container (3), and an electromechanical connection device (44) for electrical connection with the electronic control device (36).

17. The granulation apparatus according to any one of claims 1 to 16, wherein the image acquisition unit (42) is equipped with an optoelectronic structure group (45) having an image sensor (47) and an objective lens (48), and the objective lens (48) is, for the purpose, a telecentric objective lens (48a), and the telecentric objective lens (48a) is preferably configured to be bi-telecentric.

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

19. The granulation apparatus according to claim 17 or 18, wherein the image acquisition unit (42) is equipped with a positioning device (67), the positioning device (67) enables variable positioning of the optoelectronic structure group (45) which causes a change in the position of the focal plane (66) of the objective lens (48), and the positioning device (67) has an electrically operable linear module (71) which for purpose supports the optoelectronic structure group (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 device (76) having an annular illuminator (76a) in particular, which is provided to illuminate an area to be image-captured within the process chamber (4).

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

22. The granulation apparatus according to any one of claims 1 to 21, wherein the electronic control device (36) includes an electronic data processing device (78), the electronic data processing device (78) is configured for image processing of images captured by the image acquisition unit (42) in particular in a series of images, and the electronic data processing device (78) is capable of performing calculations of granule-related result values, in particular the average particle diameter of the granule particles (12) and / or the particle size distribution of the granule particles (12) and / or the median particle diameter.

23. The granulation apparatus according to claim 22, characterized in that the electronic data processing device (78) is configured such that, in order to calculate granule-related result values, the granule particles (12) that are located at the focal plane of the image acquisition unit (42) among the granule particles (12) that can be seen in the captured image are identifiable as reference granule particles (12a), and only these identified reference granule particles (12a) can serve as the basis for calculating granule-related result values, and the reference granule particles (12a) are configured for image processing such that, for the purpose of measuring, the particle size of the reference granule particles, particularly the circumference of the reference granule particles, can be electronically measured.

24. The granulation apparatus according to claim 22 or 23, characterized in that the electronic control device (36) includes an electronic operating state adjustment device (81), the electronic operating state adjustment device (81) is configured to adjust variable operating parameters affecting the operating state of the granulation process based on adjustment signals provided by an electronic data processing device (78) based on granule-related result values.

25. The granulation apparatus according to claim 24, wherein the electronic control device (36) includes a closed-loop control device (85) configured as a component of the electronic data processing device (78), the closed-loop control device (85) is capable of generating an adjustment signal for the electronic operating state adjustment device (81) based on a comparison of granule-related result values ​​provided by the data processing device (78) with pre-stored target values, and the target values ​​can be set individually for the purpose by prior input using the input device (83) of the electronic control device (36).

26. The granulation apparatus according to any one of claims 1 to 25, characterized in that the electronic control device (36) includes an electronic output device (82) capable of outputting granule-related result values ​​calculated by the electronic data processing device (78), the electronic output device (82) includes a display device (82a) that visualizes the result values ​​in particular, and the electronic output device (82) is also configured to output other process-related information for the purpose.

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

28. A granulation method for producing granules (11) consisting of a large number of granular particles (12), wherein a granulation process involving particle growth is carried out in a process chamber (4) defined by the container wall (5) of a process container (3), the granulation process is monitored using an electrically controllable image capture unit (42), a two-dimensional image of the granules (11) is captured by the image capture unit (42), the image is then evaluated using an electronic control device (36), and in accordance with the evaluation of the image, variable operating parameters that affect the operating state of the granulation process are used to set these parameters. A granulation method characterized by capturing an image as an inline image during the granulation process in which granules (11) growing in the process chamber (4) are progressing.

29. The granulation method according to claim 28, characterized in that an image of the granules (11) inside the process chamber (4) is created 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 the electronic control device (36) is used to perform image processing on the image captured by the image capture unit (42), and the image processing is used to calculate granule-related result values, in particular, the average particle diameter and / or particle size distribution and / or median particle diameter of the granule particles (12), and an adjustment signal is generated based on the granule-specific result values, and a variable operating parameter that affects the operating state of the granulation process is set by the adjustment signal.

31. The granulation method according to claim 30, characterized in that an adjustment signal is generated using closed-loop control based on a comparison between granule-related result values ​​and a preset target value.

32. The granulation method according to claim 30 or 31, characterized in that, in order to calculate granule-related result values, the granule particles (12) that are located at the focal plane (66) of the image acquisition unit (42) are identified as reference granule particles (12a) from among the granule particles (12) that can be seen in the captured image, only the identified reference granule particles (12a) are used as the basis for calculating granule-related result values, and for this purpose, image processing is performed such that the particle size of the reference granule particles (12a) is measured electronically, particularly with respect to the circumference of the reference granule particles (12a).

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

Images