Chocolate Tempering Machine Control System for Consistent Crystallization
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing tempering machines for continuous chocolate mass processing require complex operator expertise to set individual temperature and quantity controllers in coordination, often reaching the limits of their control ranges, making it difficult to achieve the desired degree of tempering due to fluctuations in input conditions and varying chocolate types and fat content.
Innovation Solution
A method and tempering machine that use a control device with a processor to set and adjust individual controller parameters based on a desired tempering degree setpoint, comparing actual and target values to continuously correct deviations, allowing for simplified operation and maintaining constant tempering without requiring extensive operator experience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If individual controllers for temperatures and quantities of tempering media are coordinated manually, then the desired degree of tempering can be achieved, but the operation becomes complex and requires extensive operator experience
Solution Approach 1:
The control device automatically determines optimal setpoint parameters for multiple controllers based on measured mass properties (temperature, viscosity, composition) and adjusts them without operator intervention. The system serves itself by continuously monitoring mass characteristics and autonomously coordinating all temperature and quantity controllers to maintain the desired tempering degree.
Solution Approach 2:
The control device dynamically changes setpoint parameters of individual controllers based on real-time mass properties. Instead of fixed manual settings, the system continuously adjusts temperature and quantity parameters of tempering media controllers according to measured viscosity, temperature, and composition variations in the chocolate mass.
2Adaptability or versatility
If controllers are adjusted to extend control ranges, then more flexibility is achieved, but the system reaches limits where temperature control medium becomes insufficient
Solution Approach 1:
The control device dynamically adapts setpoint parameters within available control ranges rather than attempting to extend them. When approaching controller limits, the system automatically adjusts other parameters and redistributes control demands across available controllers to maintain reliable temperature control without exceeding physical limitations of the tempering media.
Solution Approach 2:
The control device proactively monitors controller setpoint positions and predicts when limits will be reached. Before controllers become insufficient, the system pre-adjusts other parameters and redistributes control demands to prevent reaching unreliable operating regions where temperature control medium becomes inadequate.
3Stability of the object's composition
If multiple controllers are coordinated to handle input fluctuations, then tempering stability improves, but the setting process requires extensive operator expertise
Solution Approach 1:
The control device continuously measures mass properties (temperature, viscosity, composition) and uses this feedback to automatically adjust all controller setpoints. This closed-loop feedback system replaces complex manual coordination with automated real-time adjustments, maintaining stable tempering despite input fluctuations while eliminating the need for operator expertise in coordinating multiple controllers.
Solution Approach 2:
The control device serves multiple functions simultaneously: it measures mass properties, determines optimal setpoint parameters for all controllers, coordinates temperature and quantity controls across multiple stages, and adapts to different chocolate types. This single multi-functional control system replaces the need for multiple specialized operator skills for coordinating individual controllers.
4Manufacturing precision
If individual controller settings are optimized for specific conditions, then tempering precision improves, but the system cannot adapt to varying chocolate types and fat content
Solution Approach 1:
The control device automatically changes setpoint parameters for all controllers based on measured mass properties including fat content and chocolate type characteristics. Instead of fixed settings optimized for specific conditions, the system continuously adapts temperature and quantity parameters to match the actual composition and requirements of each chocolate batch, maintaining precision across varying types.
Solution Approach 2:
The control system transitions from static optimized settings to dynamic adaptation. The control device continuously monitors mass properties and adjusts controller parameters in real-time according to the specific characteristics of each chocolate type and batch, enabling the system to maintain precise tempering control across varying conditions without requiring manual re-optimization.
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 continuous processing of chocolate mass with consistent tempering quality, simplifying the operation of temperature control machines and ensuring the desired degree of tempering is maintained, even with variations in input conditions and chocolate types, by automatically adjusting controller settings within safe ranges.
Implementation Method 1
determining setpoint parameters for controlling the individual controllers for temperatures and quantities of the mass and the tempering media depending on the selection variable from a processor
Implementation Method 2
it is important to influence the mass, in particular in terms of temperature, in particular first to cool it and then to reheat it, so that a sufficiently large number of crystals that are as stable as possible is formed
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The method for controlling crystallization during continuous preparation of fatty masses (4) such as chocolate masses to be processed using tempering media with an individual controller for the temperature and quantity of the masses and a tempering machine (1) having the tempering media, comprises inputting a desired tempering grade target value (11) in a regulating device (7), and selecting a selection matrix by a tempering grade regulator (8) of the regulating device independent of a selection size and the inputted desired tempering grade target value. The method for controlling crystallization during continuous preparation of fatty masses (4) such as chocolate masses to be processed using tempering media with an individual controller for the temperature and quantity of the masses and a tempering machine (1) having the tempering media, comprises inputting a desired tempering grade target value (11) in a regulating device (7), selecting a selection matrix by a tempering grade regulator (8) of the regulating device independent of a selection size and the inputted desired tempering grade target value, providing several selection parameters by the selection matrix independent of the selection size and the inputted desired tempering grade target value, selecting several characteristic maps by the selection matrix independent of the selection size and the inputted desired tempering grade target value, providing several target value parameters from a processor (9) for controlling the individual controller by the characteristic maps independent of the selection parameters and the inputted desired tempering grade target value, determining a tempering grade actual value of the tempered masses, comparing the determined tempering grade actual value with the desired tempering grade target value, differencing the tempering grade target value and the tempering grade actual value for obtaining the selection size, assigning the target value parameter to the concerned controller and the tempering media, and repeating the process steps except the inputting step up to the correlation of the tempering grade target value with the determined tempering grade actual value, where constant input conditions of the masses and the tempering media are allocated at an entrance of the tempering machine. The limits of the control ranges of the controller are monitored and the characteristic maps are selected independent of the reaching of the limits of the control ranges of the controller, where the characteristic maps provide the target value parameters, which do not affect the limits of the control ranges of the controller. The control parameters of the individual controller or all controllers and/or the actual value of the temperatures of the masses are led back to the characteristic maps. An independent claim is included for a tempering machine for continuous preparation of fatty masses such as chocolate masses to be processed using tempering media to control crystallization.