2K Cartridge Mixing Rod Control for Reproducible Viscous Mixing
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Solution Overview
Problem
Existing mixing devices for 2K cartridges in the aerospace industry face challenges in achieving high accuracy and reproducible mixing results, especially with viscous materials, as they require manual effort and lack standardized mixing parameters.
Innovation Solution
A mixing device with translatory and rotational movements of components, driven by electric motors, ensures homogeneous mixing by injecting one component into another, using a control unit to adapt to different cartridges and materials, and includes sensors for real-time monitoring and adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual mixing is performed by injecting hardener with a rod and rotating the cartridge, then the mixing process can be performed without specialized equipment, but the process becomes very exhausting, slow, and requires a lot of force when mixing very viscous materials wherein standardized mixing parameters cannot be ensured
Solution Approach 1:
The patent replaces manual mechanical mixing operations with an automated mixing device that uses a drive mechanism to rotate the cartridge and a plunger to inject the hardener component. This substitution eliminates the need for manual force application while maintaining standardized mixing parameters, thereby improving productivity without sacrificing the simplicity of the overall process.
Solution Approach 2:
The mixing device is designed to perform all mixing operations automatically once the cartridge is loaded. The drive mechanism self-regulates the rotation and the plunger automatically injects the hardener in the correct amount, eliminating the need for continuous manual intervention and enabling standardized mixing parameters to be consistently maintained.
2Manufacturing precision
If standardized mixing parameters are to be ensured for high accuracy mixing results, then automated mixing devices with controlled movements are required, but the device complexity increases with multiple drive units and control systems
Solution Approach 1:
The mixing device is segmented into distinct functional modules: a drive unit for rotation, a plunger mechanism for hardener injection, and a control unit for coordination. Each module performs a specific function, which simplifies the design and control of each individual component while achieving the overall goal of precise mixing through their coordinated operation.
Solution Approach 2:
The control unit serves multiple functions: it controls the drive mechanism's rotation speed and duration, regulates the plunger's injection timing and amount, and coordinates the sequence of operations. This multi-functionality reduces the need for separate control systems for each component, thereby managing device complexity while maintaining manufacturing precision.
3Extent of automation
If pneumatic drives are used for mixing components in the cartridge, then the mixing process can be automated, but the mixing quality may not be sufficient for very viscous materials requiring high accuracy mixing ratios
Solution Approach 1:
The patent replaces pneumatic drive systems with a mechanical drive unit that directly rotates the cartridge and a mechanically actuated plunger that injects the hardener. This mechanical system provides more precise control over rotation speed, injection timing, and injection amount, which is critical for achieving accurate mixing ratios with very viscous materials while maintaining automation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The device provides high-quality, reproducible mixing results with reduced human effort, ensuring complete mixing and preventing errors through automated control and monitoring.
Implementation Method 1
a first drive unit for translatory movement of the mixing rod relative to the cartridge between a first target position and a second target position
Implementation Method 2
at least one second drive unit for rotational movement of the first mounting relative to the second mounting
Implementation Method 3
at least a third drive unit for translatory movement of the injection plunger relative to the mixing rod
Data Source
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AI summary
The present invention provides a mixing device (100) for preparing a ready-to-use mass consisting of at least two components (12, 14) which are to be mixed before use, wherein the at least one first component (12) is stored in a cartridge (11) and the at least one second component (14) is stored in a tube-shaped mixing rod (13) extending into the cartridge (11), with the cartridge (11) having a storage and mixing chamber (15), an cartridge plunger (27) moveable by an equilibrating piston (4), and with a mixing head (20) arranged in the storage and mixing chamber (15) and wherein the tube-shaped mixing rod (13) is arranged in the storage and mixing chamber (15) so as to be movable in a translatory movement (B) and rotational movement (C) and with an injection plunger (3) for positioning within the mixing rod (13), comprising a first mounting (1) for receiving the cartridge (11), a second mounting (2) for receiving the mixing rod (13), at least one first drive unit (7) for translatory movement (B) of the mixing rod (13) relative to the cartridge (11) between a first target position and a second target position, at least one second drive unit (8) for rotational movement (C) of the first mounting (1) and the second mounting (2), at least a third drive unit (9) for translatory movement (D) of the injection plunger (3) relative to the mixing rod (13), and a method for operating the mixing device (100).