Formulation Mixer and Buffer Tank for Precise Property Adjustment
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Solution Overview
Problem
Existing production systems for formulations, such as paints, face challenges in accurately adjusting properties due to non-constant raw material profiles and limited dosing accuracy, leading to time-consuming and impractical adjustments by adding starting materials, which can only compensate in one direction.
Innovation Solution
A production system comprising a small-volume process mixer and a buffer tank, connected via fluid-conducting piping, allows for continuous production and precise adjustment of formulations by monitoring and controlling the mass flow of input materials, enabling efficient mixing and homogenization, and iterative adjustments to achieve target properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If adjustments are made by adding starting materials to compensate for deviations, then the target state can be approached, but the adjustment is limited to one direction and requires extensive time
Solution Approach 1:
The system performs preliminary action by determining the actual state of input materials before they are fully processed and adjusts the recipe specifications in advance. This allows the production process to be corrected proactively rather than requiring time-consuming post-production adjustments, directly reducing adjustment time while maintaining precision.
Solution Approach 2:
The system implements feedback by continuously determining the actual state of input materials and comparing it with target specifications. Based on this feedback, the recipe specifications are dynamically adjusted to compensate for deviations, enabling precise property adjustment without extensive time loss.
2Adaptability or versatility
If the property profiles of raw materials vary, then the actual state of produced material deviates from target state, but subsequent adjustments are impractical for certain properties
Solution Approach 1:
The system determines the actual state of input materials with varying property profiles before production and adjusts recipe specifications in advance. This preliminary action enables the system to adapt to different material properties proactively, avoiding impractical post-production adjustments and maintaining manufacturing precision across various material variations.
Solution Approach 2:
The system changes parameters by dynamically adjusting recipe specifications based on the actual state of input materials. When material properties deviate from targets, the system modifies dosing quantities and production parameters to compensate, enabling versatile adaptation to different material profiles while maintaining precise control over final product properties.
3Measurement precision
If weighing and dosing of input materials is performed with limited accuracy, then deviations in material properties occur, but increasing dosing accuracy increases system complexity
Solution Approach 1:
The system implements feedback by determining the actual state of input materials and using this information to adjust recipe specifications. This feedback mechanism compensates for limited dosing accuracy without requiring complex high-precision dosing equipment, as the system adapts to actual material states rather than relying solely on precise initial dosing.
Solution Approach 2:
The system performs self-service by automatically determining material states and adjusting recipe specifications without requiring complex external intervention. The automated feedback loop compensates for dosing limitations while maintaining simplicity in the overall system architecture.
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 system enables effective, precise, and adaptable production of formulations, reducing the need for subsequent adjustments and significantly improving the efficiency and speed of achieving desired material properties, particularly in the production of color and effect paints.
Implementation Method 1
They usually contain one or more mixing containers (process mixers) in which the components of the material to be produced are mixed together
Implementation Method 2
buffer tank for mixtures, preferably liquid mixtures, left out of the process mixer (kP)
Data Source
AI summary
The invention relates to a production system comprising a unit (1) which comprises a sub-unit (1.1) for continuously producing formulations. The sub-unit (1.1) comprises a combination of a small-capacity process mixer and a buffer tank, means for feeding a defined amount of a substances into the process mixer, a measuring device for determining properties of a partial charge of a formulation produced in the process mixer, an evaluation device for determining a variation of properties of partial charges produced in the process mixer from the properties of a pre-defined desired state and a device for adapting the supply of substances taking into account the variations. The present invention also relates to a method for producing formulations.