Bench Mixer Infrared Sensor Control for Automated Whipping Process
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Solution Overview
Problem
Existing bench mixers lack the ability to automatically monitor and adjust the mixing process in real-time, requiring manual intervention to determine when modifications or termination are needed, which complicates processes like whipping egg whites or mixing dough.
Innovation Solution
Incorporating an infrared sensor and processor that emit and detect a beam to measure the reflection intensity and distance of the mixture's surface, allowing for automated control of the mixing motor based on changes in the mixture's state, such as volume or reflectivity, to determine optimal endpoint conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual monitoring of mixing process is used, then operational simplicity is maintained, but productivity and precision are reduced due to continuous manual intervention required
Solution Approach 1:
The mixing system performs self-monitoring through the sensor that continuously detects mixture properties, and self-adjustment through automated motor control based on detected parameters, eliminating the need for manual intervention while maintaining optimal mixing conditions
Solution Approach 2:
The sensor provides continuous feedback about the mixture state (volume, consistency, or color) to the controller, which automatically adjusts motor operation in response to detected changes, creating a closed-loop control system that improves productivity without increasing operational complexity
2Measurement precision
If automated sensor-based control is implemented, then productivity and precision are improved, but device complexity increases due to addition of sensor and controller components
Solution Approach 1:
The patent replaces manual visual inspection and mechanical monitoring with an optical or electromagnetic sensor that non-contactlessly detects mixture properties, substituting a simple mechanical/electronic sensing system for complex manual monitoring procedures
Solution Approach 2:
The sensor system is designed to detect multiple mixture parameters (volume, consistency, color) using a single sensing mechanism, and the controller integrates multiple control functions, reducing overall system complexity through multi-functionality
3Manufacturing precision
If continuous monitoring is performed, then manufacturing precision is improved, but energy consumption increases due to constant sensor operation and processing
Solution Approach 1:
Instead of truly continuous monitoring, the system performs periodic measurements at strategically chosen intervals during the mixing process, maintaining sufficient precision while reducing energy consumption associated with constant sensing and processing
Solution Approach 2:
The system establishes baseline mixture characteristics before full mixing begins, allowing the controller to predict optimal mixing duration and intensity, thereby reducing unnecessary energy consumption while maintaining precision through targeted monitoring
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
Enables precise and automated control of mixing processes, ensuring that whipping reaches a stable volume or dough formation is complete, reducing manual effort and improving consistency by using moving averages and lowpass filtering to filter out noise and determine the appropriate stopping or adjustment of the mixing process.
Implementation Method 1
a sensor to produce a sensor beam to be directed at the interior so as to produce a reflection from the substance in the interior and to produce a signal indicative of the reflection
Data Source
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AI summary
A bench or stand mixer (100) that receives a bowl (105) that contains ingredients (106). A motor (102) drives an accessory (beater) (103) to process the ingredients (106). A sensor (109) provides a signal indicative of a change in the ingredients, with the sensor (109) cooperating with a controller (processor) (110) to control the speed of the motor (102), in response to the change in condition of the ingredients (106).