Extrusion Device Density Control for Vegetable Block Production
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Solution Overview
Problem
Existing production facilities for extruded blocks face challenges in maintaining consistent strand and billet density due to external and internal influences, leading to density fluctuations and economic disadvantages from excess material.
Innovation Solution
A production device equipped with a detection device and control system that adjusts the extrusion device to maintain consistent block quality by determining density after the separating device, using a steaming device for heat treatment and hydraulic drive for precise process control, and employing non-contact sensors for continuous density measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the extrusion device is adjusted to deliver minimum required strand density with a safety reserve, then the minimum block quality criteria are met, but excessive densities and associated excess material occur
Solution Approach 1:
A detection device measures the actual density of extruded blocks in real-time and feeds this information back to a control system, which adjusts extrusion parameters dynamically. This closed-loop feedback mechanism eliminates the need for excessive safety reserves while ensuring minimum quality criteria are consistently met.
Solution Approach 2:
The system dynamically changes extrusion parameters (such as pressure, speed, or temperature) based on detected density variations. By continuously adjusting these parameters in response to actual measurements, the system achieves consistent block quality without maintaining a fixed safety margin that would cause excess material.
2Manufacturing precision
If density detection is performed after the separating device, then quick and specific reaction to quality fluctuations is possible, but the detection and control system complexity increases
Solution Approach 1:
The patent employs non-contact detection methods (such as optical or radiometric sensors) to measure block density, replacing complex mechanical measurement systems. This substitution reduces mechanical complexity while enabling continuous, real-time density monitoring after the separating device for quick reaction to quality fluctuations.
Solution Approach 2:
The detection and control system is integrated into the existing production line, utilizing the natural movement and positioning of blocks through the separating device. The system leverages the self-organizing flow of materials through the production process, requiring minimal additional infrastructure while achieving precise density control.
3Loss of substance
If the security margin is reduced to minimize excess material, then economic disadvantages are minimized, but the risk of quality fluctuations increases
Solution Approach 1:
Real-time density detection with feedback control enables the system to maintain quality consistency without excessive safety margins. The continuous monitoring and dynamic adjustment ensure that blocks meet minimum quality criteria even with reduced margins, eliminating the trade-off between security margin and quality reliability.
Solution Approach 2:
The system transitions from static, pre-set extrusion parameters to dynamic, real-time parameter adjustment based on actual measurements. This dynamic approach allows the system to respond instantly to variations, maintaining reliability with reduced security margins by actively compensating for fluctuations rather than relying on conservative pre-planning.
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 allows for tighter tolerances and reduced security margins, minimizing excess material and economic losses by quickly addressing density fluctuations and ensuring consistent block quality.
Implementation Method 1
the heat energy required for curing the forming agent is largely or completely introduced into the strand and released by condensation
Implementation Method 2
A good way to do this is to determine the density by weighing the blocks
Implementation Method 3
using a non-contact sensor system that works with radiation measurement, for example
Implementation Method 4
A hydraulic drive of the extrusion device, in particular a hydraulic cylinder for an extrusion piston, is also advantageous for process control
Data Source
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AI summary
The invention relates to a production device (1) for blocks (4). It consists of an extrusion device (2), comprising a hydraulically driven strand generator (5) for producing a strand-shaped, intermittently moved strand (3) made of fine vegetable particles mixed with binding agent and a cutting device (7) for severing blocks (4) from the strand (3). The production device (1) comprises a detection device (8) disposed downstream of the cutting device (7) in the production direction (15) for the weight of the blocks (4), and a controller (9) for influencing the extrusion device (2) and for controlling the strand density. The detection device (8) can be designed as a weighing device (8'), in particular as a belt weigher. The invention further relates to a production method for blocks (4) that are severed from a strand (3). The bar-shaped strand (3) made of fine vegetable particles mixed with binding agent is produced by extrusion and is intermittently advanced. After cutting, the weight of the blocks (4) is detected and the strand density is controlled depending on the detection result. The blocks (4) can be bent individually or in groups.