Masterbatch Feed Control Using Spectral Color Feedback
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Solution Overview
Problem
Current systems for controlling the color of plastic products in industrial processes face challenges due to the complexity of accurately and reliably achieving target colors, as they rely on empirical set-points and are sensitive to variations in pigment and resin properties, leading to inefficiencies and material waste.
Innovation Solution
A method that determines optical spectral properties of both the manufactured part and the target color, adjusts pigment feed rates based on these properties, and uses feedback loops to ensure color consistency, employing spectrometers for calibration-free differential measurements to control the feed of color masterbatches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional color control systems use predetermined color formulations and control over feed rate parameters, then color accuracy can be achieved, but the system complexity increases and requires precise calibrations specific to each unique setup
Solution Approach 1:
The system implements a feedback control loop where a spectrometer measures the actual color of manufactured parts in real-time, compares the measured color to the target color, and automatically adjusts the masterbatch feed rate to minimize color deviation. This closed-loop feedback mechanism eliminates the need for complex predetermined formulations and setup-specific calibrations by continuously self-correcting the color output.
Solution Approach 2:
The patent replaces complex mechanical calibration systems with optical measurement and automated control. Instead of using predetermined formulations requiring precise mechanical setup and manual calibration for each part type, the system uses spectrometric measurement and automated feed rate adjustment to achieve color accuracy, significantly simplifying the overall system complexity.
2Manufacturing precision
If trial-and-error approaches are used to determine pigment concentrations, then color targets can be achieved, but material waste increases and production time is lost
Solution Approach 1:
The system performs preliminary color measurement on the manufactured part immediately after production using a spectrometer. This real-time measurement allows for immediate feedback and adjustment of the masterbatch feed rate, eliminating the need for trial-and-error approaches where multiple test runs are required. The color accuracy is achieved in the first attempt rather than through iterative testing.
Solution Approach 2:
The closed-loop feedback system continuously monitors the actual color output and automatically adjusts the masterbatch feed rate to maintain color accuracy. This real-time correction prevents material waste by avoiding over-production of off-color parts and eliminates the need for trial-and-error testing that consumes additional materials.
3Manufacturing precision
If trial-and-error approaches are used to determine pigment concentrations, then color targets can be achieved, but production efficiency decreases due to labor intensity and time consumption
Solution Approach 1:
The system performs self-measurement and self-correction of color deviations. The spectrometer automatically measures the color of manufactured parts, and the control system automatically adjusts the masterbatch feed rate without requiring operator intervention. This automation eliminates labor-intensive trial-and-error procedures and significantly improves production efficiency while maintaining color accuracy.
Solution Approach 2:
The patent replaces manual trial-and-error procedures with automated optical measurement and control systems. The spectrometer and automated feed rate adjustment eliminate the need for operator involvement in color matching, reducing labor intensity and accelerating production while maintaining precise color control.
4Ease of manufacture
If volumetric feeders are used to dispense masterbatch, then simplicity is maintained, but accuracy deteriorates due to variances in density and granule size
Solution Approach 1:
The system implements feedback control where the actual color measurement of the manufactured part is used to adjust the masterbatch feed rate. This compensates for variations in masterbatch density and granule size by dynamically adjusting the feed rate to achieve the target color, maintaining accuracy despite the simplicity of the volumetric feeder.
Solution Approach 2:
The system dynamically changes the masterbatch feed rate parameter based on real-time color measurement feedback. When density or granule size variations cause color deviations, the control system automatically adjusts the feed rate to compensate, maintaining color accuracy without requiring complex gravimetric feeding mechanisms.
5Manufacturing precision
If gravimetric feeders are used to dispense masterbatch, then dispensing accuracy is improved, but device complexity increases due to additional weighing mechanisms
Solution Approach 1:
The system uses color feedback from spectrometric measurement to control the masterbatch feed rate, replacing the need for complex gravimetric weighing mechanisms. The feedback loop automatically adjusts the feed rate based on actual color output, achieving dispensing accuracy through optical measurement rather than mechanical weighing, thereby reducing device complexity.
Solution Approach 2:
The patent replaces mechanical weighing mechanisms with optical measurement and automated control. Instead of using gravimetric feeders that require complex weighing and measurement systems, the invention uses spectrometric color measurement and automated feed rate adjustment to achieve equivalent or superior dispensing accuracy, significantly reducing device complexity.
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 approach enables precise and consistent production of target colors by dynamically adjusting pigment feed rates, reducing material waste and improving efficiency by normalizing control parameters for all colors, thus overcoming the limitations of existing methods.
Implementation Method 1
determining optical spectral properties of a manufactured part
Implementation Method 2
determining at least one pigment control parameter based on a relationship of the optical spectral properties of the manufactured part to the optical spectral properties of the target color
Data Source
AI summary
Systems and methods are provided for controlling a color masterbatch feed rate in production of a manufactured part to match a color of the manufactured part to a target color by adjusting a concentration of masterbatch that is mixed with a raw material and fed into a processing machine for producing the manufactured part. Control of the color masterbatch feed rate is based on optical spectral properties of an in-line manufactured part, a known reference part having the target color, and an algorithm for calculating and adjusting the color masterbatch feed rate.