Food Product Mold With Integrated Sensor Measurement Unit
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Solution Overview
Problem
Molds used in food product manufacturing face challenges such as mechanical, thermal, and chemical stress, leading to fatigue and potential contamination of products, resulting in costly delays and increased safety measures due to empirical design and lack of real-time monitoring capabilities.
Innovation Solution
A mold equipped with a measurement unit that includes sensors to collect and transfer data on mechanical parameters like stress, strain, and acceleration, allowing for real-time monitoring and optimization of the mold design and production process, enabling early detection of potential failures and improved hygiene.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If molds are designed with high safety factors to avoid failures, then reliability is improved, but the mold size increases and becomes heavier and harder to move
Solution Approach 1:
The patent applies preliminary action by installing sensors and measurement units on the mold before production begins. These devices continuously monitor mechanical parameters such as stress, strain, and acceleration, allowing the actual load conditions to be measured in advance. This enables optimization of the mold design based on real data rather than conservative estimates, potentially reducing unnecessary weight while maintaining reliability.
Solution Approach 2:
The patent implements feedback mechanisms through sensors that continuously monitor the mold's mechanical state during production. The measured data on stress, strain, and acceleration is processed to provide feedback on actual load conditions. This feedback loop enables dynamic adjustment of safety factors and optimization of mold design, allowing for lighter molds that maintain adequate reliability based on actual performance data rather than worst-case assumptions.
2Device complexity
If molds are designed without detailed knowledge of loads and environmental influences, then device complexity is reduced, but reliability deteriorates due to empirical design
Solution Approach 1:
The patent introduces measurement units and sensors as intermediary devices between the mold and the design optimization process. These intermediaries collect real data on mechanical parameters, environmental conditions, and production processes. The data from these intermediaries is then used to refine the mold design, creating a bridge between empirical observations and theoretical design optimization, thereby improving reliability without excessive complexity.
Solution Approach 2:
The patent replaces empirical mechanical design methods with data-driven optimization. Instead of relying on conservative safety factors and empirical rules, the system uses sensor data to actually measure the mechanical loads and environmental influences. This substitution of empirical design with measured data enables more precise and reliable mold design while reducing unnecessary complexity.
3Reliability
If real-time monitoring of mold parameters is implemented, then reliability is improved through early detection of failures, but device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the monitoring system into separate functional components: sensors for measuring mechanical parameters, data processing units for analyzing the information, and alert systems for detecting failures. This modular segmentation allows each component to be optimized independently and facilitates easier implementation and maintenance, reducing overall system complexity while maintaining high reliability through comprehensive monitoring.
4Reliability
If production is halted to check for chipped-off material, then safety is improved, but productivity decreases
Solution Approach 1:
The patent applies preliminary action by continuously monitoring mold integrity through sensors during production. The system detects signs of material degradation or chipping in real-time, allowing preventive measures to be taken before actual contamination occurs. This enables production to continue uninterrupted while maintaining food safety, as the system proactively identifies and addresses potential issues before they become problems requiring production halts.
Data Source
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AI summary
A mold for forming at least one food product with a measurement unit, wherein the mold has a filling side and a back side opposite to said filling side. Further, the measurement unit comprises: measuring means configured to measure at least one parameter while the mold is used in a production line or testing facility and a data transfer interface configured to transfer data to an external processing unit.