Granulation Drive Torque Control for Variable Shear
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Solution Overview
Problem
Existing granulation devices and methods cannot influence or set the granulate properties, such as particle size, during the ongoing process, limiting control over the granulation process and product quality.
Innovation Solution
A device and method that provide a uniformly high drive torque over the entire rotational speed range, allowing for variable shear forces and direct control over granulate properties by using a drive unit like a hydraulic, servo, or torque motor, combined with a chopper and particle size measuring systems to monitor and adjust granulate particle size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional drive units are used with limited torque at low rotational speeds, then the device structure remains simple, but the granulate properties cannot be influenced and set during the ongoing process
Solution Approach 1:
The patent applies parameter changes by transitioning from conventional drive units with fixed torque-speed characteristics to advanced drive units (hydraulic motors, servo motors, torque motors) that can dynamically adjust torque output across the rotational speed range. This enables the shear forces in the granulation process to be varied, allowing direct setting of granulate properties such as particle size during the ongoing process.
2Shape
If the mixer rotational speed is reduced to produce larger granulates, then the granulate particle size increases, but the drive torque becomes insufficient to mix tough and viscous granulating masses
Solution Approach 1:
The patent resolves this contradiction by using advanced drive units that maintain high torque output even at low rotational speeds. This enables the mixer to operate at reduced speeds to produce larger granulates while still providing sufficient drive torque to mix tough and viscous granulating masses, effectively decoupling the trade-off between speed and torque.
3Manufacturing precision
If conventional motors are used, then the device structure remains simple, but the shear forces cannot be varied to directly set granulate properties
Solution Approach 1:
The patent implements precise manufacturing precision for granulate particle size by using advanced drive units with sophisticated control systems. These systems can dynamically adjust the rotational speed and torque parameters to vary shear forces during granulation, enabling direct setting and precise control of granulate properties such as particle size distribution.
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
Enables the direct setting of granulate properties like particle size, ensures consistent mixing of tough and viscous granulating masses, and improves product quality by allowing precise control over the granulation process, including the production of uniform pellets and reduced idle phases.
Implementation Method 1
a uniformly high drive torque by the drive unit over its entire rotational speed range allows the shear forces, which are proportional to the mixer rotational speed, to be changed or varied
Implementation Method 2
allows the shear forces, which are proportional to the mixer rotational speed, to be changed or varied in the granulation process
Data Source
AI summary
Described is a device for granulating a powder to be granulated or a powder mixture to be granulated. The device includes at least one working vessel in which the powder to be granulated or the powder mixture to be granulated is provided, at least one mixer for mixing the powder to be granulated or the powder mixture to be granulated, at least one dosing device for granulating liquid, and at least one drive unit that includes a rotational speed range for providing a drive torque required for the mixer. The drive unit provides a uniformly high drive torque over its entire rotational speed range. Also described is a method for granulating a powder to be granulated or a powder mixture to be granulated using such a device.