Concurrent Liquid Batching With Optical Mixing Feedback
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Solution Overview
Problem
Current batching processes in the flavors and fragrances industry are space and time-intensive, requiring substantial human intervention, leading to inefficiencies and potential human errors, and existing automated systems are slow and costly.
Innovation Solution
A batching system utilizing a vessel, mixer, pump, optical sensor, and microprocessor-controlled mass flow meters and valves, allowing for concurrent introduction and recirculation of liquid materials until fully mixed, with automated dispensing and a clean-in-place subsystem, integrated with AI for quality control and inventory management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manual batching processes are used, then flexibility and adaptability are maintained, but the process becomes time-intensive and space-consuming
Solution Approach 1:
The patent replaces manual mechanical operations with an automated robotic system featuring a mobile robot equipped with sensors, actuators, and automated pouring mechanisms. The robot autonomously navigates, identifies materials, and performs batching operations without human intervention, dramatically reducing batch cycle time while maintaining operational flexibility.
Solution Approach 2:
The system enables self-service through autonomous robotic operation where the robot independently performs material retrieval, identification, measurement, and pouring without requiring human operators to move between stations. The automated optical inspection and control systems further enable self-monitoring and self-correction, eliminating time-consuming manual processes.
2Reliability
If automated batching systems are implemented, then human error is reduced, but the system becomes complex and costly
Solution Approach 1:
The mobile robotic system serves multiple functions: navigation, material identification, measurement, pouring, and cleaning, all within a single platform. This multi-functionality reduces the need for separate specialized equipment, thereby managing complexity while achieving high reliability through automated error-free operations.
Solution Approach 2:
The system incorporates optical sensors and inspection systems that provide real-time feedback on material properties, pouring accuracy, and mixing homogeneity. This feedback loop enables automated adjustments and verification, ensuring consistent quality and reducing errors while maintaining manageable system complexity through intelligent control.
3Ease of operation
If multiple separate stations are used for batching operations, then process control is maintained, but substantial floor space is required
Solution Approach 1:
The patent merges multiple separate batching stations into a single mobile robotic system that can move between material storage locations and mixing vessels. This consolidation integrates material retrieval, measurement, and pouring functions into one unit, dramatically reducing floor space requirements while maintaining process control through automated procedures and sensor monitoring.
Solution Approach 2:
The system transitions from static separate stations to a dynamic mobile robot that can reposition itself as needed. The robot's mobility allows it to access different materials and vessels without requiring dedicated fixed stations, optimizing space utilization while maintaining operational control through programmable sequences and real-time monitoring.
4Adaptability or versatility
If manual material handling is performed, then adaptability to different formulations is maintained, but human intervention increases process time
Solution Approach 1:
The system performs preliminary actions by pre-programming batching procedures for different formulations and pre-positioning materials. The robot retrieves materials and prepares them for mixing according to predetermined sequences, enabling quick adaptation to different formulations without manual reconfiguration, thereby maintaining versatility while improving batching efficiency.
Solution Approach 2:
The system adapts to different formulations by changing operational parameters such as material quantities, pouring rates, and mixing conditions through software control. This parameter-based adaptability allows the same robotic hardware to handle diverse formulations efficiently, maintaining formulation flexibility while eliminating the time loss associated with manual adjustments.
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
The system significantly reduces batch cycle times, minimizes space requirements, and enhances efficiency by automating the process, reducing human error, and optimizing resource utilization through real-time monitoring and predictive analytics.
Implementation Method 1
an optical sensor...until a reading from the optical sensor indicates that the at least forty Liquid Materials are fully mixed
Implementation Method 2
at least forty microprocessor-based mass flow meters...concurrently introduced into the vessel via gravity feed via the mass flow meters
Implementation Method 3
repeatedly circulating the Liquid Materials through, in sequence, the vessel, a mixer, a pump
Implementation Method 4
the vessel, the mixer, the pump and the optical sensor are coupled together by piping so as to form a circuit within which at least 40 Liquid Materials, concurrently introduced into the vessel...will re-circulate while being mixed by the mixer
Data Source
AI summary
A batching system involves a vessel, a mixer, a pump, an optical sensor, at least forty microprocessor-based mass flow meters and at least forty automated valves each controlled by one of the mass flow meters, wherein each of the at least forty microprocessor-based mass flow meters are coupled to the vessel; and wherein the vessel, the mixer, the pump and the optical sensor are coupled together so as to form a circuit within which Liquid Materials, concurrently introduced into the vessel, will re-circulate until at least one reading from the optical sensor indicates that the materials are fully mixed. A batching method involves concurrently introducing into a vessel, through at least forty microprocessor-controlled mass flow meters, Liquid Materials to be mixed, and repeatedly circulating the Liquid Materials through, in sequence, the vessel, a mixer, a pump, and an optical sensor, until the at Liquid Materials are fully mixed.