Coffee Densifier Load Feedback for Consistent Bulk Density
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Solution Overview
Problem
Industrial coffee grinders face limitations in achieving high coffee density without overheating the coffee and excessive energy consumption, as well as inconsistent density control, which affects downstream packaging requirements.
Innovation Solution
A method involving a coffee densifier with a mixing chamber and a discharge door that adjusts based on the mixer motor load to control coffee density, using a controller to move the discharge door and adjust the residence time of coffee grounds, thereby optimizing density and energy usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If paddle mixing is used to increase coffee density, then coffee bulk density is improved, but excessive heat is generated which over roasts the coffee
Solution Approach 1:
The patent replaces traditional paddle mixing with a screw conveyor system that uses rotational mechanical action to agitate and densify coffee. The screw conveyor's helical geometry provides gentler mixing action compared to paddles, reducing frictional heating while still achieving increased bulk density through controlled agitation and compression during conveyance.
Solution Approach 2:
The patent introduces a jet pump system using compressed air (pneumatics) to create a fluidized bed of coffee grounds in the mixing chamber. This pneumatic agitation method replaces mechanical paddle contact, allowing coffee particles to be lifted and redistributed by air flow, which reduces direct mechanical friction and heat generation while maintaining effective mixing and densification.
2Volume of stationary object
If paddle mixing is used to increase coffee density, then coffee bulk density is improved, but unnecessary drag on the mixing motor occurs
Solution Approach 1:
The patent replaces the high-drag paddle mixing system with a screw conveyor mechanism that is mechanically optimized for efficient material handling. The screw conveyor's design allows it to move and agitate coffee with lower motor power requirements, as the helical structure naturally propels material along its length while providing mixing action, reducing the energy burden on the drive motor.
Solution Approach 2:
The patent uses compressed air through jet pumps to create pneumatic agitation and fluidization of coffee grounds. This pneumatic system replaces mechanical paddle mixing, transferring the mixing function to air flow rather than direct motor-driven mechanical contact, thereby significantly reducing the drag and energy consumption of the mixing motor while maintaining effective coffee densification.
3Manufacturing precision
If discharge door position is adjusted to control coffee density, then coffee density consistency is improved, but system complexity increases
Solution Approach 1:
The patent implements a feedback control system where a sensor continuously monitors the density of coffee exiting the densifier and sends this information to a controller. The controller automatically adjusts the discharge door position based on the measured density, creating a closed-loop system that maintains consistent output density. This automated feedback mechanism simplifies operation while achieving precise density control.
Solution Approach 2:
The patent employs a density sensor and automated control system that enables the densifier to self-regulate its operation. The system automatically detects density variations in the output coffee and adjusts the discharge door position without operator intervention, allowing the equipment to maintain optimal performance autonomously and reducing the need for manual monitoring and adjustment.
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
The solution achieves higher coffee density with reduced energy consumption and maintains consistent coffee density output, enhancing the efficiency and adaptability of coffee processing for packaging applications.
Implementation Method 1
measuring a mixer motor load on a mixer motor driving mixing members agitating the ground coffee in the mixing chamber
Implementation Method 2
The discharge door is moved when the mixer motor load is outside a predefined mixer motor load operating range
Data Source
AI summary
A method of controlling coffee density exiting from a coffee densifier is disclosed. The method includes the steps of feeding a ground coffee into a mixing chamber having a discharge door. A mixer motor load on a mixer motor driving mixing members agitating the ground coffee in the mixing chamber is measured. The discharge door is moved when the mixer motor load is outside a predefined mixer motor load operating range.