Continuous Blender With Adjustable Blade Orientation
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Solution Overview
Problem
Existing continuous blenders for pharmaceutical manufacturing require replacement of blades and impellers when blending efficiency is inadequate or when drug formulations change, leading to halted manufacturing processes and economic losses.
Innovation Solution
A continuous blender with retrofittable blades that can change orientation while in operation, allowing for adjustment of mixing conditions without affecting discharge flow velocity, and featuring sensors for real-time monitoring and control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If blades are fixed in orientation, then manufacturing precision is maintained, but adaptability deteriorates
Solution Approach 1:
The blade orientation is made dynamic and adjustable during operation. The patent describes blades that can change their angle of orientation relative to the impeller axis, allowing the mixing system to adapt to different formulation requirements while maintaining optimal mixing performance for each specific application.
Solution Approach 2:
The patent changes the orientation parameter of the blades to optimize mixing for different formulations. By adjusting the blade angle, the system can adapt to various material properties and mixing requirements without sacrificing the precision and homogeneity of the mix, as each formulation can have its optimal blade orientation configured.
2Loss of time
If discharge opening size is adjusted to control mixing conditions, then mixing time changes, but discharge flow velocity varies causing erratic operation
Solution Approach 1:
Instead of changing the discharge opening size, the patent changes the blade orientation parameter to control mixing conditions. This allows mixing time to be adjusted by modifying the blade angle while keeping the discharge opening constant, thereby maintaining stable discharge flow velocity and reliable operation of downstream equipment.
3Manufacturing precision
If entire continuous mixer is replaced for formulation changes, then mixing precision is maintained, but productivity deteriorates due to halted manufacturing
Solution Approach 1:
The patent segments the impeller into multiple independent blade elements that can be individually adjusted or replaced. This allows formulation-specific optimizations without replacing the entire continuous mixer, enabling quick changes while maintaining manufacturing precision and avoiding production halts.
Solution Approach 2:
The blade orientation is made adjustable during operation, allowing the system to adapt to different formulations without replacement. This dynamic capability enables continuous manufacturing to proceed uninterrupted while maintaining optimal mixing precision for each formulation through blade reconfiguration.
4Adaptability or versatility
If blade orientation is changed during operation, then adaptability improves, but device complexity increases
Solution Approach 1:
The impeller is segmented into multiple independent blade elements mounted on a common shaft. Each blade can be independently oriented or replaced, providing configuration flexibility without requiring a completely complex new mechanism. The segmented design allows simple attachment and adjustment of individual blades while maintaining overall system simplicity.
Data Source
AI summary
The present disclosure relates to a blender having blades whose orientation angle is changeable, even while the blender is in operation. The blender 100 includes a housing 110 with inlets (140a, 140b) to allow inflow of ingredients and an outlet (140c) to allow outflow of blended ingredients. The blender 100 incorporates an external shaft 122 with the blades 123 rotatably coupled to it, and an internal shaft 121 inside the external shaft 122. The blender 100 incorporates a first driving unit 130 to rotate the external shaft 122 and blades 123 about a direction along a length of the housing 110 to allow blending of the ingredients. The internal shaft 121 having engaging means coupled to back of the blades 123 such that a linear displacement of the internal shaft 121 using a second driving unit 121, enables change in orientation of the blades 123.