Mixer Control Method Using Power Feedback for Consistency

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Solution Overview

Problem

Existing mixers for concrete, mortar, powders, and granulates face challenges in optimizing mixing times, achieving consistency and homogeneity, reducing wear and maintenance, and providing real-time feedback for corrective actions, while also monitoring the mixing tank's state and efficiency.

Innovation Solution

A control method that communicates input data related to the mix formulation to a control unit, detects electric power characteristics, processes data to calculate active and reactive power, and compares these values with thresholds to determine the consistency and homogeneity of the mix, allowing for adaptive control of the mixing cycle and maintenance operations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If mixing time is extended to improve consistency and homogeneity, then product quality improves, but energy consumption and operating costs increase

Engineering Contradiction:

Improveconsistency and homogeneity of mixVSAvoidelectric energy consumption

Core Design Contradiction:

Manufacturing precisionVSUse of energy by moving object

Solution Approach 1:

The control unit continuously monitors electric current absorption and active power during mixing, using this feedback to determine when the mix has reached the desired consistency and homogeneity. This allows the system to automatically stop mixing at the optimal moment, avoiding unnecessary energy consumption while ensuring product quality requirements are met.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces traditional mechanical timing-based control with an electrical parameter-based control system. Instead of running the mixer for a predetermined time, the system uses electric current and power measurements to detect mixing state, substituting mechanical time-based control with electrical sensing and automated decision-making.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If mixing time is reduced to save energy and time, then operating costs decrease, but product quality and homogeneity may be compromised

Engineering Contradiction:

Improvemixing cycle timeVSAvoidconsistency and homogeneity of mix

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The system uses real-time feedback from electric current and power sensors to monitor the mixing process. This feedback mechanism allows the system to identify the precise moment when the mix achieves the desired quality, enabling early termination of mixing without compromising product consistency and homogeneity.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The control unit autonomously determines when mixing is complete based on electrical parameter analysis, without requiring external intervention or predetermined timing. The system serves itself by automatically detecting the optimal stop point and controlling the drive unit accordingly.

Inventive Principle:

Principle #25Self-service

3Reliability

If traditional current and power monitoring is used for safety alarms, then equipment protection is provided, but mixing optimization and quality control are not achieved

Engineering Contradiction:

Improveequipment safety and protectionVSAvoidmixing cycle optimization

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The control unit performs multiple functions simultaneously: it monitors electric current and power for both equipment protection (safety alarms) and mixing process optimization (quality control). This multi-functional approach allows the same sensing system to serve both protective and productive purposes, eliminating the need for separate systems.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent merges the safety monitoring function with the mixing optimization function into a single integrated control system. The same electric current and power measurements used for safety alarms are also used to determine mixing quality and optimize the mixing cycle, combining previously separate functions into one unified system.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS12257739B2Method to control a mixer and corresponding mixer

Publication Date: 2025.03.25 OFF MEC GALLETTI O M G SRL

AI summary

A method to control a mixer includes an input to a control and command unit including a plurality of input data correlated to a formulation of a mix, a detection step to detect the values of an electric quantity characteristic of the electric power line of a drive unit in the mixer, a processing step where data is processed to calculate the overall active power, and to carry out verifications, comparing the data processed with one or more of the respective data introduced among the input data, in order to transmit to a controller that commands the mixer, a consent signal to discharge the mix or an anomaly signal.