Foamed Construction Material Device with Automated Flow Control
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Solution Overview
Problem
Existing devices for producing foamed building materials struggle to maintain a consistent output due to changing environmental and input conditions, such as ambient conditions in a production hall or storage conditions of components, leading to variations in the volume of air inclusions and pore size.
Innovation Solution
The device incorporates sensors to detect temperature and air pressure, both before and after mixing, allowing for the adjustment of volume and mass flows, as well as the introduction of input energy, to ensure consistent foaming results. This includes a foam generation unit for even mixing and a sealed mixing chamber to prevent external influences, with automated control using reference values stored in a memory unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If volume flows and mass flows are set based on fixed parameters, then the device operates simply, but the output result varies with changing ambient conditions and input conditions
Solution Approach 1:
The control unit receives actual values from sensors measuring temperature, pressure, and volume flows, compares these with target values, and automatically adjusts the mass flow of suspension and volume flow of gas to compensate for deviations caused by changing ambient conditions, ensuring consistent output density and pore structure
Solution Approach 2:
The patent replaces manual adjustment of flow parameters with an automated control system that uses electronic sensors and actuators to regulate the mixing process, substituting mechanical manual control with electronic feedback-based automation to maintain precision under varying conditions
2Manufacturing precision
If sensors and automated control are added to detect and compensate for changing conditions, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
Temperature sensors, pressure sensors, and flow sensors continuously monitor the mixing process parameters, and the control unit uses this feedback to automatically adjust suspension mass flow and gas volume flow, ensuring precise control of dispersion density and foam pore structure despite ambient condition variations
Solution Approach 2:
The control system dynamically adjusts critical parameters including the mass flow of suspension, volume flow of gas, temperature of components, and pressure conditions to maintain optimal mixing ratios and ensure consistent foamed material properties under varying environmental conditions
3Manufacturing precision
If the mixing chamber is sealed to prevent external influences, then manufacturing precision is improved, but ease of operation decreases
Solution Approach 1:
The mixing chamber employs sealable connections and flanges that maintain a closed system during operation to prevent ambient air contamination, while allowing for disassembly and access when maintenance or cleaning is required, balancing sealing integrity with operational accessibility
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 solution enables the production of foamed building materials with consistent properties by compensating for changing conditions, ensuring uniform volume flows and maintaining production quality across varying environmental and input conditions.
Implementation Method 1
the volume of the air inclusions and the pore size in the foamed building materials can be controlled
Implementation Method 2
mix the gas supplied by the gas supply unit with a liquid, resulting in the formation of a foam
Data Source
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Figure 2
AI summary
The invention relates to a device (110) for producing foamed construction materials, comprising a gas supply unit (112), a suspension supply unit (150-156) and a mixing chamber (118). The device (110) also comprises an open-loop and/or closed-loop control unit (136), which has means (116, 124, 130, 134, 146) for supplying values of a plurality of input parameters, on the basis of which at least the temperature of the dispersion and the air pressure in the surroundings of the device (110) can be inferred. The open-loop and/or closed-loop control unit (136) is also designed to influence at least one output parameter, by means of which the ratio of the volumes and/or masses and/or densities of gas and suspension fed per unit time can be set. The invention further relates to a corresponding method.