Mixer Outlet Mass Flow Prediction Under Weight Sensor Interference
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing mixing device systems face challenges in reliably detecting mass flows and product tracking, especially in transient states, due to interference in weight measurements, which affects the sorting of defective products and leads to unnecessary waste.
Innovation Solution
A method that measures the product inlet mass flow and predicts the weight and outlet mass flow using a mathematical model, with corrections based on measured values, allowing for dynamic and precise recording of mixing behavior in both steady and transient states.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If weight sensors are used to measure product mass in the mixing device, then mass measurement is possible, but measurement precision deteriorates due to strong interference in horizontally aligned mixing devices
Solution Approach 1:
The patent introduces a mathematical model as an intermediary that indirectly determines mass flow and product mass by using measurable parameters (power consumption, mass flow rates at inlets/outlets) to calculate values that cannot be directly measured, thereby avoiding the interference problem of direct weight sensing in horizontal mixing devices
Solution Approach 2:
The patent replaces the mechanical/physical weight measurement system with a computational approach using a mathematical model that processes electrical measurements (power consumption) and flow measurements to derive mass information, substituting direct mechanical sensing with indirect computational determination
2Reliability
If slow filters are used to process weight measurement signals, then measurement reliability improves, but productivity deteriorates due to low dynamic range and inability to measure outside steady state
Solution Approach 1:
The patent replaces the filtering-based signal processing approach with a mathematical model-based computational approach that can dynamically track mass flow and product mass in real-time during both steady-state and transient operations, eliminating the need for slow filtering that limits dynamic response
Solution Approach 2:
The patent implements a dynamic mathematical model that continuously adapts to changing operating conditions, allowing reliable product tracking during transient states when the system is changing, rather than only during steady-state conditions, thereby enabling real-time responsiveness without sacrificing reliability
3Loss of information
If direct measurement of outlet mass flow is attempted, then complete product tracking is possible, but device complexity increases due to additional sensors and measurement points
Solution Approach 1:
The patent uses a mathematical model as an intermediary calculation engine that derives outlet mass flow and product mass information from measurements taken at the inlet (mass flow rates) and power consumption data, eliminating the need for direct physical sensors at the outlet while maintaining complete product tracking capability
Solution Approach 2:
The mathematical model enables the system to self-determine outlet mass flow and product mass characteristics using only inlet measurements and power consumption data, making the system self-sufficient without requiring additional outlet sensors or measurement infrastructure
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a method for operating a mixing device of a plant in which powdered product is processed into products, wherein different powdered products are fed into the mixing device, and wherein the different products are mixed in the mixing device to form a mixed product before being processed into products, wherein the product inlet mass flow rate flowing into the mixing device and the weight of the product in the mixing device are measured, wherein the weight of the product in the mixing device and the product outlet mass flow rate flowing out of the mixing device are predicted from the measured product inlet mass flow rate using a mathematical model, and wherein the prediction of the product outlet mass flow rate generated using the mathematical model is corrected on the basis of the measured weight of the product in the mixing device.