Automated Dough Rheometer Calibration Using Reference Flour
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Solution Overview
Problem
Current dough rheometers lack a standard, traceable material for calibration due to varying rheological and material properties of different flour types and batches, leading to inconsistent measurements across different devices, causing unnecessary flour rejection and increased costs.
Innovation Solution
An automated calibration system for dough rheometers that uses a known flour type and moisture content to generate a time-dependent and flour-dependent adjustment model, allowing for consistent measurements across different rheometers by comparing torque curve data from reference and field devices, enabling real-time calibration and reducing variability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If different rheometers are used to measure flour properties, then measurements can be performed at multiple locations, but measurement precision deteriorates due to lack of calibration standards
Solution Approach 1:
The patent introduces a calibration flour with known, stable rheological properties as an intermediary standard. This calibration flour serves as a mediator between the rheometer and unknown flour samples, enabling consistent measurements across different devices by providing a reference point for calibration and validation.
Solution Approach 2:
The patent changes the parameters of the calibration flour to have extremely stable and known rheological properties that differ from regular flour. By controlling moisture content, particle size distribution, and composition, the calibration flour maintains consistent torque values across different rheometers, enabling precise calibration.
2Measurement precision
If calibration standards are established, then measurement precision improves, but device complexity increases due to additional calibration procedures
Solution Approach 1:
The rheometer performs self-calibration by automatically comparing measurements of the calibration flour against predetermined reference values. The system autonomously adjusts its measurement parameters and generates calibration factors without requiring manual intervention or complex external calibration equipment.
Solution Approach 2:
The calibration flour is prepared in advance with precisely controlled properties (moisture content, particle size, composition) and stored ready for use. The reference torque values are predetermined through preliminary characterization, allowing rapid calibration without time-consuming setup procedures.
3Ease of manufacture
If manual calibration procedures are used, then ease of manufacture is maintained, but productivity decreases due to time-consuming calibration processes
Solution Approach 1:
The patent replaces manual mechanical calibration procedures with an automated computational system. The rheometer automatically performs measurements, compares results to reference values, calculates calibration factors, and adjusts measurement parameters using software algorithms, eliminating time-consuming manual operations.
Solution Approach 2:
The calibration process is integrated into the normal measurement workflow, allowing continuous operation. The rheometer can perform calibration measurements quickly during routine operations without interrupting productivity, and the automated system maintains continuous measurement capability across different samples and time periods.
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 system ensures consistent and accurate measurements of flour properties across various rheometers, reducing unnecessary flour rejection and costs by providing a calibrated measurement of rheological properties and mixing characteristics, enhancing comparability and reproducibility of results.
Implementation Method 1
one or more torque sensors for generating a time-varying measurement of sample torque encountered by one or more of the one or more mixing blades when mixing the sample mixture in the mixing container
Data Source
AI summary
Described herein are systems and methods for the automated adjustment of flour property measurement equipment such as dough rheometers. The systems and methods allow measurements of flour and dough to be performed on different rheometers with consistent results, regardless of the manufacturer or location of the rheometers. The systems and methods described herein allow a second rheometer, for example, that is deployed in the field to provide results that are consistent with a first dough rheometer, for example, that may be at a different location, or the same location but of the same or different manufacturer. The systems and methods can be used to calibrate, remotely and in real-time, dough rheometers that are deployed in various locations.