Ice Cream Coating Weight Control via Feedback Loop
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Solution Overview
Problem
Existing production processes for coated ice cream products struggle with precise control of the weight of chocolate coatings, leading to deviations from experimental values during final production.
Innovation Solution
A production facility with a supply station and a coating station, utilizing multiple carriers with clamps to transport ice cream products, and equipped with weight equipment for automatic weighing before and after coating. This setup uses a feedback loop to adjust coating parameters such as chocolate temperature, ice cream temperature, and dipping time based on weight data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If coating parameters are adjusted based on experimental values, then coating weight can be controlled, but deviations from target values occur during final production
Solution Approach 1:
The patent implements a feedback control system where the actual coating weight is measured during production and used to adjust coating parameters in real-time. The controller receives signals from weight measurement and automatically adjusts parameters such as coating time, chocolate temperature, and dipping speed to maintain target coating weight, thereby eliminating deviations between experimental and production values.
Solution Approach 2:
The system dynamically changes coating parameters (coating time, temperature, dipping speed) based on measured coating weight deviations. The controller automatically adjusts these parameters during production to compensate for variations and maintain precise coating weight control, resolving the inconsistency between experimental and production results.
2Quantity of substance
If thick chocolate coatings are applied to ensure adequate coating weight, then coating coverage is improved, but production costs increase significantly
Solution Approach 1:
The feedback control system measures the actual coating weight and adjusts the coating process to apply only the necessary amount of chocolate. By continuously monitoring and adjusting coating parameters, the system prevents both under-coating and over-coating, ensuring adequate coverage while minimizing chocolate waste and controlling production costs.
Solution Approach 2:
The system optimizes coating parameters (reducing coating time, adjusting temperature, modifying dipping speed) to achieve the minimum required coating weight with less chocolate material. This eliminates the need to apply excessively thick coatings, thereby reducing chocolate consumption and production costs while maintaining adequate coating coverage.
3Manufacturing precision
If coating parameters are adjusted during production to achieve precise weight control, then coating precision is improved, but production time increases
Solution Approach 1:
The feedback control system performs weight measurement and parameter adjustment automatically and continuously during production without interrupting the coating process. The rapid automatic adjustments maintain precise coating weight control while keeping production speed high, as the system operates in real-time without requiring manual intervention or process stoppages.
Solution Approach 2:
The coating process continues uninterrupted while the feedback control system continuously measures and adjusts parameters. The automatic control enables simultaneous coating application and parameter optimization, maintaining both high production speed and precise coating weight control without sequential delays.
4Measurement precision
If experimental procedures are used to determine correct coating formulation and timing, then initial coating accuracy is achieved, but uncertainties remain during final production
Solution Approach 1:
The system transitions from open-loop experimental procedures to closed-loop feedback control during production. Actual coating weight is continuously measured and fed back to the controller, which automatically adjusts parameters to compensate for production variations. This eliminates the uncertainties inherent in experimental methods and ensures consistent accuracy during final production.
Solution Approach 2:
While experimental procedures provide preliminary guidance for coating formulation and timing, the feedback control system performs real-time adjustments during production to account for actual variations. This combination uses experimental data as a starting point but relies on continuous feedback to eliminate uncertainties and ensure consistent results.
Data Source
AI summary
In a production facility for coating ice cream products a plurality of carriers are used for transport of the ice cream products from the supply station to a coating station where coating, for example chocolate, is applied to the product. The production facility includes weight equipment configured for automatically weighing the ice cream products before and after application of the coating, which is used in a feedback loop for adjusting the coating parameters, for example chocolate temperature.