Metering Supply Line Mixing for Continuous Liquid Batch Changes
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Solution Overview
Problem
Existing metering systems struggle to maintain consistent metering results when different batches of liquids with varying properties are used, requiring cleaning or complete parameter adjustment, which disrupts continuous production.
Innovation Solution
A method and apparatus for continuously supplying a metering device by progressively adding new batches to old batches, allowing for controlled adaptation of metering parameters to minimize property changes, using a common supply line and controlled pumps to mix media in a laminar flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If different batches of liquid medium are supplied to the metering device, then production continuity is maintained, but abrupt changes in media properties occur that cannot be compensated by parameter adjustment
Solution Approach 1:
The control unit initiates a progressive mixing process before the batch change is complete, gradually introducing the new batch medium mixed with the old batch medium. This preliminary action smooths the transition of media properties, allowing the metering device to adapt continuously without abrupt changes that would compromise metering result consistency.
Solution Approach 2:
The system changes the composition parameter of the liquid medium progressively by mixing old and new batches in varying ratios over time. This gradual parameter change in the medium composition enables continuous adaptation of metering parameters while maintaining consistent metering results throughout the batch transition.
2Reliability
If cleaning or replacement of guiding components is performed during batch change, then media property changes are reset, but production interruption occurs
Solution Approach 1:
The mixing process occurs continuously within the supply line during normal operation, eliminating the need to stop production for cleaning or replacement. The useful action of medium supply continues uninterrupted while the composition transitions gradually from old batch to new batch through controlled mixing.
3Adaptability or versatility
If metering parameters are completely readjusted during batch change, then adaptation to new medium properties is achieved, but production interruption and time loss occur
Solution Approach 1:
The metering parameters are dynamically adjusted in real-time based on the progressive mixing ratio of old and new batches. Instead of static complete readjustment, the system continuously adapts parameters during the transition, reducing the time required while maintaining adaptability to changing medium properties.
4Speed
If new batch is added abruptly to old batch, then batch change is fast, but abrupt changes in material parameters occur that cannot be compensated
Solution Approach 1:
The batch transition is executed as a periodic process with gradually changing mixing ratios over time. The control unit implements a time-based progression where the proportion of new batch medium increases systematically, ensuring smooth transitions in material parameters while maintaining relatively fast overall batch change speed.
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 uninterrupted production with consistent metering results by smoothing transitions between batches through gradual parameter adjustments, eliminating the need for cleaning or complete reconfiguration.
Implementation Method 1
using a common supply line and controlled pumps to mix media in a laminar flow
Data Source
AI summary
In a method for continuously supplying a metering device with different batches of one and the same liquid medium, a progressive addition of the medium of a new batch takes place during a batch change.