Formulation Mixing With Feedback Correction of Part-Batch Deviations
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Solution Overview
Problem
Existing production systems for formulations, such as paints, face challenges in accurately adjusting material properties due to non-constant feedstock profiles, leading to time-consuming batch adjustments and limited directional correction capabilities.
Innovation Solution
A production system comprising a process mixer, buffer tank, measurement unit, and evaluation unit that allows for the determination and correction of property deviations in part-batches, enabling precise adjustments of feedstock amounts to achieve the target state through a combination of a process mixer and buffer tank, with automated feedback loops for continuous improvement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If adjustment is made by addition of feedstocks to material manufactured, then the target state can be established, but adjustment is possible only in one direction and compensating for too low viscosity by addition of resin components and additives is impracticable
Solution Approach 1:
The invention applies preliminary action by determining the actual state of material manufactured and calculating the required adjustments before completing the batch manufacture. This allows the system to pre-calculate the necessary feedstock additions or removals to achieve the target state, enabling bidirectional adjustment rather than being limited to post-manufacturing correction in one direction only.
Solution Approach 2:
The system implements feedback by continuously determining the actual state of material manufactured and using this information to adjust feedstock addition calculations. The evaluation unit receives data about the actual state and feeds it back into the calculation process, allowing real-time correction of deviations from the target state through optimized feedstock addition plans.
2Manufacturing precision
If the entire manufacturing process comprising actual batch manufacture and subsequent adjustment is conducted, then the target state can be achieved, but the process is very time-consuming
Solution Approach 1:
The invention significantly reduces production time by performing the determination of actual state and calculation of adjustments during or immediately after batch manufacture, rather than requiring a separate post-manufacturing adjustment phase. The system pre-calculates the optimal feedstock addition plan based on actual measurements, allowing for rapid correction without extending the overall production cycle.
Solution Approach 2:
The system maintains continuity of useful action by integrating the determination and calculation steps into the manufacturing flow. Rather than stopping production for separate adjustment operations, the system continuously monitors and calculates adjustments, enabling seamless transition from manufacturing to correction without idle time or process interruptions.
Data Source
AI summary
The present invention relates to a production system for manufacturing of formulations, comprising a unit (1). The unit (1) includes a subunit (1.1) which includes a combination of a process mixer and a buffer tank, means of feeding defined amounts of feedstocks into the process mixer, a measurement unit for ascertaining properties of a part-batch of a formulation manufactured in the process mixer, an evaluation unit for determining a deviation of properties of the part-batches manufactured in the process mixer from the properties of a predefined target state, and a unit for adjusting the feed of feedstocks in view of the deviations. The present invention also relates to a process for manufacturing formulations.