Cocoa Bean Shell Separation via Optical Feedback Control

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Solution Overview

Problem

Existing methods for separating shells and nibs from legumes, such as cocoa beans, require frequent and costly adjustments to air classifier settings to maintain optimal shell content, which is time-consuming and inefficient.

Innovation Solution

Incorporating image recording devices and a display device to monitor the separation process, allowing for real-time adjustments of conveyor screen speed and air flow, with a control device connected to the crusher and air classifier arrangements to maintain optimal product quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If manual sampling and adjustment of air classifier settings is used to maintain optimal shell content, then product quality can be maintained, but the process is time-consuming and expensive

Engineering Contradiction:

Improveshell content controlVSAvoidadjustment time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent replaces manual mechanical sampling and visual inspection with an automated optical image recognition system. Cameras capture images of the separated material, and image processing algorithms automatically analyze shell content, eliminating the need for manual sampling and adjustment while maintaining precise quality control

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system implements continuous feedback by constantly monitoring the separated material with image recording devices and using the analyzed data to automatically adjust air classifier settings in real-time, ensuring optimal shell content without manual intervention

Inventive Principle:

Principle #23Feedback

2Manufacturing precision

If frequent sampling and adjustment is performed to maintain quality, then shell content can be optimized, but production efficiency decreases

Engineering Contradiction:

Improveseparation qualityVSAvoidproduction speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The image recording devices continuously monitor the separation process without interrupting production flow. The system performs real-time analysis and continuous adjustment, eliminating the need to stop production for manual sampling and adjustment, thus maintaining both high quality and productivity

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The system performs self-adjustment by automatically analyzing images of the separated material and modifying air classifier settings based on the analyzed shell content, eliminating the need for operator intervention and maintaining continuous production

Inventive Principle:

Principle #25Self-service

3Measurement precision

If manual quality checking is used, then cost-effective monitoring is possible, but the process is labor-intensive and less accurate

Engineering Contradiction:

Improvequality detection accuracyVSAvoidmonitoring system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces manual visual inspection with automated optical sensors and image processing systems. Cameras and image analysis algorithms provide more precise and consistent quality detection without requiring human operators, significantly improving measurement precision while the automated nature reduces long-term operational complexity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 efficient and cost-effective monitoring and adjustment of the separation process, ensuring consistent quality by quickly identifying changes and automatically optimizing the separation of shells and nibs, reducing manual sampling needs and maintaining a 5% shell content in nibs.

Implementation Method 1

at least one fan for sucking out shell parts of the legumes

Methodology Applied

Scientific EffectAir flow:

Implementation Method 2

the conveyor screen arrangement is preferably designed as a vibrating screen arrangement

Methodology Applied

Scientific EffectVibration: Vibration

Implementation Method 3

the hulls are suctioned off one or more conveyor screens in several steps using an air stream

Methodology Applied

Scientific EffectAir stream:

Implementation Method 4

at least one image recording device is provided at least for detecting shells in the region of the air sifting arrangement

Methodology Applied

Scientific EffectOptical detection:

Data Source

PatentEP3827907B1Arrangement for breaking up pulses, in particular cocoa beans, and for separating shells

Publication Date: 2025.01.01 HAMBURG DRESDNER MASCHFABEN VERW GES MBH

Figure 1

AI summary

Arrangement for breaking pulses, in particular cocoa beans (8), and for separating shells (12) and nibs (10) of the pulses, comprising a housing arrangement (4) which includes at least one crusher arrangement (6) and an air classifier arrangement (36), wherein the air classifier arrangement (36) includes at least one conveying screen arrangement (14) movable by means of a drive device and at least one suction device (58, 60) with at least one blower for suctioning shell parts of the pulses, wherein at least one image acquisition device (72, 74, 76, 78, 80) is provided at least for detecting shells (12) in the area of the air classifier arrangement (36), such that a determination of the volumetric quality of the separation is possible.