AI-Controlled Industrial Extruder for Material-Adaptive Processing
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Solution Overview
Problem
Existing extrusion processes face challenges in optimally selecting and designing extruders for specific applications due to limitations in understanding material characteristics, rheology, transformation reactions, and interactions between system design and operating parameters, particularly in food and polymer extrusion, where complex and ill-defined processes occur.
Innovation Solution
The integration of physics-informed ML-based techniques for hybrid food processing operations, which utilize machine learning models to optimize and automate extrusion processes, addressing the complexity of material interactions and process conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual or semi-automatic operation is used with operator experience-based control, then operational flexibility is maintained, but optimal control of extrusion process and material characteristics cannot be ensured
Solution Approach 1:
The patent replaces manual operator control with an automated control system that uses sensors to detect material characteristics and a control unit to automatically adjust extrusion parameters. This substitution of mechanical/manual control with automated sensing and control achieves precise control of material characteristics while eliminating dependence on operator experience.
Solution Approach 2:
The control system performs self-adjustment by automatically detecting material properties through sensors and modifying extrusion parameters without external intervention. The system serves itself by autonomously optimizing the extrusion process based on real-time material feedback, achieving consistent product quality independent of operator skill level.
2Adaptability or versatility
If complex material interactions and rheology are not adequately understood, then extruder design can be simplified, but optimal selection and design for specific applications becomes difficult
Solution Approach 1:
The patent employs a control system that dynamically adjusts extrusion parameters (temperature, pressure, screw speed) based on detected material characteristics. By changing parameters in response to material properties, the system achieves optimal performance for different applications without requiring complex manual analysis of material rheology and interactions.
Solution Approach 2:
The system uses sensors to continuously monitor material characteristics during extrusion and feeds this information back to the control unit. This closed-loop feedback enables the system to adapt to different materials and applications automatically, achieving high versatility without increasing fundamental system complexity.
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
Enhances the efficiency and effectiveness of extrusion processes by providing optimized control and automation, improving product quality and process consistency in food and polymer extrusion.
Implementation Method 1
the extruder continuously pressing the input material to and out of the shaping opening forming an output material as extrudate, according to the operating principle of the Archimedean screw
Data Source
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AI summary
An industrial smart extruder (1) and extrusion method, the industrial, intelligent extruder (1) acting as a conveying device that uniformly squeeze solid to viscous masses out of a forming orifice under high pressure and temperature according to the operating principle of the Archimedean screw, wherein material is processed by hot extrusion or cold extrusion or warm extrusion or friction extrusion or micro extrusion by the extruder (1), and wherein the material extruded by the extruder (1) at least comprises food products or metals or polymers or ceramics or concrete, or modelling clay. The industrial, intelligent extruder (1) comprises a smart device with a ML- or Al- based core engine controlling and/or steering and/or optimizing the operation of the extruder (1) automatically.