Multi-Channel Gravimetric Batch Blender Parallel Weighing
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Solution Overview
Problem
Current Remote Central Gravimetric Blender (RCGB) systems in the plastics industry are costly, space-intensive, complex, prone to contamination, and inefficient in producing uniform batches due to serial weighing and lengthy batch preparation times, with significant downtime for cleaning and potential separation of ingredients during transport.
Innovation Solution
The Multi-Channel Gravimetric Batch Blender (MCGBB) system, which features parallel weighing of components in individual units, reducing the need for extensive piping and allowing direct, contamination-minimized delivery of batches to processing machines with local mixers, and automatic cleaning to prevent contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If Remote Central Gravimetric Blender systems are used to weigh and blend raw materials, then material blending capability is achieved, but system cost, space requirements, and complexity increase significantly
Solution Approach 1:
The system divides the blending function into multiple independent weighing stations, each capable of weighing different materials simultaneously. This segmentation eliminates the need for a single complex central blender, reducing overall system complexity while maintaining blending capability.
Solution Approach 2:
Multiple weighing stations are merged into a coordinated system that feeds a common mixer, combining the simplicity of individual weighing operations with the functionality of centralized blending, thereby reducing both cost and complexity.
2Measurement precision
If serial weighing of components is used in RCGB systems, then weighing accuracy is achieved, but batch preparation time increases
Solution Approach 1:
The system segments the weighing process into parallel operations at multiple independent weighing stations, allowing simultaneous weighing of different materials. This maintains individual weighing accuracy while dramatically reducing total batch preparation time.
Solution Approach 2:
Multiple weighing stations operate continuously and simultaneously, eliminating the idle time associated with serial weighing. Each station works in parallel, ensuring that the useful action of weighing continues without interruption across the system.
3Ease of operation
If extensive piping and manual handling are used for material transport, then material delivery is achieved, but contamination risk increases
Solution Approach 1:
The system extracts materials directly from storage silos to weighing stations and then to the mixer, eliminating intermediate handling steps and extensive piping. This direct path reduces contamination risk while maintaining ease of operation.
Solution Approach 2:
The system uses automated conveyors and gravity-fed chutes to transport materials without manual handling. The materials essentially serve themselves through the system, reducing human intervention and associated contamination risks.
4Stability of the object's composition
If large buffer storage containers are used, then batch supply stability is achieved, but space requirements increase
Solution Approach 1:
Multiple weighing stations operate simultaneously and continuously, ensuring a steady supply of materials to the mixer without requiring large buffer storage. The parallel operation maintains supply stability while minimizing space requirements.
Solution Approach 2:
Materials are weighed in advance at multiple stations before being transferred to the mixer. This preliminary weighing action ensures that all components are ready simultaneously, providing batch supply stability without needing extensive buffer storage.
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 MCGBB system significantly reduces costs, space requirements, and complexity while ensuring high accuracy and throughput, minimizing contamination risks and batch separation, and eliminating the need for extensive cleaning and buffer storage, thereby enhancing production efficiency and consistency.
Implementation Method 1
Material from each bin drops into weighing hopper connected to load cell. The material from each bin is weighed separately
Implementation Method 2
the batch is sucked through the delivery pipe by a vacuum system on the processing machine
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A weighing apparatus for the preparation of a mixture of granular components that comprise batches of material required by a plurality of processing machines in a plant for the manufacture of plastic products is described. The apparatus comprises a Multi- Channel Gravimetric Batch Blender (MCGBB) configured to weigh predetermined weights of the raw materials and to combine the weighed portions of raw materials into batches according to a predetermined recipe for each processing machine and a computer that controls the operation of all components of the MCGBB. The MCGBB comprises several weighing units arranged in a way that allows material weighed in each of the weighing units to fall through individual chutes via a common funnel into a manifold that distributes the weighed batches to several processing machines via a system of delivery pipes.