Cuber Management System with Modified PID Control
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Solution Overview
Problem
The processing of tear-resistant thermoplastic materials in cubers is challenging due to fire hazards, jamming issues, and difficulty in managing complex control systems, leading to inefficiencies and increased maintenance costs, especially when integrating cellulosic fibers and thermoplastic resins into combustible products.
Innovation Solution
A graphical interface system connected to a server that monitors and controls the cuber process, using a touch screen for real-time data visualization and auditory feedback, with a modified PID algorithm for feed rate control, allowing for remote operation and automatic startup/shutdown, and simplifying maintenance tasks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If tear-resistant thermoplastic materials are processed through conventional shredders, then material processing capability is improved, but fire hazard increases due to friction and heat generation
Solution Approach 1:
The patent replaces mechanical friction-based shredding with a cubing process that uses controlled compression and forming. The cuber system applies pressure to compact shredded material into cubes without the extensive friction and heat generation that occurs in conventional high-speed shredding, thereby reducing fire hazards while maintaining processing capability
Solution Approach 2:
The patent introduces an intermediary controlled environment between shredding and final processing. The cuber system acts as an intermediary that receives shredded material and processes it under controlled conditions with monitored temperature and pressure, preventing the uncontrolled heat buildup that leads to fire hazards
2Ease of operation
If traditional switch and knob control interfaces are used for cuber management, then system control capability is improved, but operator complexity and training requirements increase
Solution Approach 1:
The patent replaces traditional mechanical switch and knob interfaces with a graphical user interface (GUI) that displays system parameters and controls visually. The GUI presents information in an intuitive format with graphical representations of system components and parameters, reducing operator complexity while maintaining full control capability
Solution Approach 2:
The patent creates a visual copy or representation of the physical cuber system through graphical icons and displays on the interface. Operators interact with graphical representations of system components rather than physical switches, making the interface more intuitive and easier to understand while providing the same control functions
3Productivity
If feed rate is increased to optimize production, then productivity is improved, but jamming frequency increases leading to more downtime
Solution Approach 1:
The patent implements a feedback control system that continuously monitors cuber load through electrical consumption signals and feed material weight. The system automatically adjusts feed rate based on real-time conditions, increasing feed rate when the cuber can handle it and reducing it when jamming risk increases, thereby optimizing both productivity and reliability
Solution Approach 2:
The patent makes the feed rate dynamic rather than fixed. The system automatically varies the feed rate based on real-time cuber performance, material characteristics, and operational conditions. This dynamic adjustment allows the system to maintain high productivity when conditions are favorable while preventing jams when the cuber is approaching its capacity limit
Data Source
AI summary
A method and system for monitoring and controlling the processing of thermoplastics. The system includes a graphical interface and a server attached to the equipment in the cubing process. The interface includes a depiction of the equipment in the cubing process. A touch screen interface allows the user to control the equipment in the cubing process. In addition, information from the equipment is transmitted to the interface and conveyed to the user either through visual displays (e.g. numerical or graphical) or auditory signals (e.g. alarms or status beeps). The server may include software used to monitor the feed rate into the cuber with a modified proportional integral derivative (PID) algorithm in which the prime feedback input is a real-time electrical consumption signal derived from the motor driving the cuber.