Dissolution Apparatus Torque-Based Viscosity Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing dissolution apparatuses face inefficiencies in separating foreign matters from waste plastic due to unpredictable characteristics of contaminants and the need for constant operation conditions, which can affect subsequent separation quality and make continuous treatment challenging.
Innovation Solution
A dissolution apparatus equipped with a torque sensor and microprocessor that calculates the viscosity of the waste resin and solvent solution, controlling the supply and heating to maintain viscosity below a predetermined value, ensuring efficient and uniform dissolution for continuous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the rotation of the stirrer is repeatedly started and stopped to prevent damage and breakage, then the reliability of the stirrer is improved, but the productivity of the dissolution process deteriorates
Solution Approach 1:
The system uses a torque sensor to detect the load torque acting on the stirrer in real-time and feeds this information back to the microprocessor. The microprocessor calculates viscosity based on the detected torque and adjusts operating parameters accordingly, enabling continuous operation without repeated start-stop cycles while preventing stirrer damage through real-time monitoring and adjustment.
Solution Approach 2:
The system dynamically changes operating parameters (solvent supply amount, heating temperature) based on real-time viscosity calculations from torque detection. By adjusting these parameters continuously, the system maintains optimal dissolution conditions without needing to stop and restart the stirrer, thus improving both reliability and productivity.
2Ease of operation
If constant operation conditions are used for dissolution, then the ease of operation is improved, but the manufacturing precision of the solution uniformity deteriorates
Solution Approach 1:
The torque sensor provides real-time feedback on the dissolution state through load torque detection. The microprocessor uses this feedback to automatically adjust solvent supply and heating parameters, maintaining solution uniformity without requiring manual intervention or complex operator judgment, thus preserving ease of operation while improving manufacturing precision.
Solution Approach 2:
The system performs self-adjustment based on real-time torque detection and viscosity calculation. The microprocessor automatically modifies operating parameters to maintain optimal dissolution conditions, eliminating the need for constant manual monitoring and adjustment while ensuring consistent solution quality.
3Device complexity
If the viscosity is not controlled within a predetermined range, then the device complexity is reduced, but the productivity of the subsequent separation process deteriorates
Solution Approach 1:
The torque sensor and microprocessor create a simple feedback loop that continuously monitors dissolution state and adjusts parameters to maintain viscosity within the optimal range. This minimal control structure ensures solution uniformity required for efficient separation without adding significant device complexity.
Solution Approach 2:
The system replaces complex mechanical viscosity measurement devices with a torque sensor that infers viscosity from the load torque on the stirrer. This substitution maintains solution uniformity for productive separation while keeping the control system simple and integrated into the existing dissolution apparatus.
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
This approach optimizes solvent addition and heating energy, ensuring uniformity of the solution for subsequent foreign matter separation processes, stabilizing separation quality and enabling efficient continuous operation.
Implementation Method 1
a torque sensor configured to detect a load torque acting on the stirrer
Implementation Method 2
a heating device configured to heat the waste resin and the solvent supplied to the dissolution tank
Implementation Method 3
a stirrer configured to stir the waste resin and the solvent, heated by the heating device
Data Source
AI summary
A dissolution apparatus configured to dissolve a waste resin in a dissolution tank with a solvent. The dissolution apparatus includes: a supply device configured to supply the waste resin and the solvent into the dissolution tank; a heating device configured to heat the waste resin and the solvent supplied to the dissolution tank; a stirrer configured to stir the waste resin and the solvent, heated by the heating device; a torque sensor configured to detect a load torque acting on the stirrer; and a microprocessor. The microprocessor is configured to perform: calculating a viscosity of a solution of the waste resin and the solvent based on the load torque detected by the torque sensor, and controlling at least one of the supply device and the heating device such that the viscosity calculated in the calculating becomes less than a predetermined value.