Dual-Sensor Syrup Mixing Control for Accurate BRIX Correction
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Solution Overview
Problem
Existing liquid mixing systems in the beverage industry face challenges in maintaining consistent product quality due to fluctuations in flavoring substance concentrations, leading to potential waste from incorrect mixtures.
Innovation Solution
A liquid mixing system with a mixing regulator, separate lines for base and admix components, and sensors for real-time concentration and BRIX value measurement, using a control unit to adjust the mixing ratio based on corrected BRIX values to ensure precise control of flavoring compounds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a BRIX sensor is used to measure the concentration of flavoring substances in syrup, then the mixing ratio can be controlled, but the measurement is falsified by the presence of other chemical compounds leading to incorrect composition determination
Solution Approach 1:
The measurement task is segmented into two separate functions: a BRIX sensor measures total dissolved solids, while a first sensor (spectroscopic, conductivity, or temperature) measures specific interfering compounds. The control unit then segments the correction process by calculating the falsified portion and subtracting it from the total BRIX signal to isolate the true flavoring substance concentration.
Solution Approach 2:
The system implements feedback control by continuously monitoring the syrup composition with dual sensors, comparing the measured values against target concentrations, and automatically adjusting the mixing regulator via the control unit to maintain accurate flavoring substance levels in the final product.
2Stability of the object's composition
If the mixing ratio is adjusted to compensate for concentration fluctuations, then product quality consistency is maintained, but waste increases due to discarding incorrectly mixed products
Solution Approach 1:
The system performs preliminary measurement and correction of the syrup concentration before mixing occurs. By measuring the actual flavoring substance concentration upfront and pre-calculating the required mixing ratio adjustment, the system prevents incorrect mixing from occurring in the first place, thereby avoiding waste generation.
Solution Approach 2:
Real-time feedback from the sensors allows the control unit to continuously adjust the mixing ratio to compensate for concentration variations, ensuring that the final product consistently meets quality specifications without generating waste from out-of-spec mixtures.
3Measurement precision
If multiple sensors are used to measure different parameters, then measurement accuracy is improved, but device complexity increases
Solution Approach 1:
The control unit serves multiple functions: it processes signals from both sensors, performs the mathematical correction calculation, controls the mixing regulator, and monitors product quality. This multi-functionality reduces the need for separate dedicated components for each task, thereby limiting the increase in overall device complexity.
Solution Approach 2:
The control unit acts as an intermediary that integrates the measurements from the BRIX sensor and the first sensor, performs the necessary calculations to correct for interference, and translates this information into control signals for the mixing regulator, simplifying the system architecture by centralizing the intelligence.
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 solution minimizes waste by ensuring accurate determination and control of the liquid product's composition, maintaining consistent flavoring compound concentrations and product quality.
Implementation Method 1
a first sensor for measuring the concentration of a chemical compound in the component to be admixed are arranged in the second line
Implementation Method 2
a BRIX sensor for measuring a BRIX value of the component to be admixed are arranged in the second line
Data Source
Figure 1
Figure 2
AI summary
A liquid mixing system for mixing components for a liquid product, comprising a mixing controller for mixing the components and a feed comprising at least two separate lines, wherein a base component can be supplied to the mixing controller in a first line and a component to be added in a second line, wherein upstream of the mixing controller in the second line a first sensor for determining the concentration of a chemical compound in the component to be added and a BRIX sensor for determining a BRIX value of the component to be added are arranged, and wherein a control unit is provided which can control the mixing of the components by the mixing controller depending on the measured concentration and the measured BRIX value.