Optical Particle Size Distribution Analysis for Material Board Mixtures
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Solution Overview
Problem
Sieve analysis for determining particle size distribution in mixtures is complex, time-consuming, and provides only a snapshot, failing to offer real-time insights during production processes.
Innovation Solution
An optical system captures images of the mixture, which are transformed using Fourier analysis to generate characteristic curves, allowing direct determination of size distribution parameters without physical separation or sieving, enabling rapid and frequent analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sieve analysis is used to determine particle size distribution, then measurement precision is achieved, but device complexity and time consumption increase significantly
Solution Approach 1:
The patent replaces the mechanical sieve analysis system with an optical measurement system. Instead of using physical sieves to separate particles, the invention uses optical instruments (such as cameras or sensors) to capture images of particles and electronically determines size distribution through image processing algorithms, thereby eliminating the complex mechanical sieve system while maintaining measurement capability
Solution Approach 2:
The patent creates an optical copy (image) of the particle mixture instead of physically separating particles. By capturing images of particles and using image processing to analyze size distribution, the system avoids the need for physical sieve separation, reducing device complexity while preserving measurement precision
2Measurement precision
If sieve analysis is used to determine particle size distribution, then measurement accuracy is obtained, but analysis time increases significantly
Solution Approach 1:
The patent enables continuous optical measurement of particle size distribution during the production process, eliminating the need to stop production for periodic sieve analysis. The optical system can continuously capture and analyze particle images in real-time, providing continuous data without interrupting the manufacturing process
Solution Approach 2:
By replacing the time-consuming mechanical sieving process with rapid optical imaging and electronic analysis, the system reduces analysis time from minutes or hours to seconds, allowing for real-time monitoring without physical separation
3Measurement precision
If sieve analysis is used, then size distribution data is obtained, but real-time monitoring capability is lost
Solution Approach 1:
The patent replaces the slow mechanical sieving process with rapid optical measurement, enabling real-time monitoring. The optical system can quickly capture images and process size distribution data instantaneously, providing real-time feedback during production rather than delayed snapshot data
Solution Approach 2:
By using optical copying (imaging) instead of physical separation, the system enables rapid, real-time analysis of particle size distribution without interrupting the production flow, achieving both measurement precision and real-time monitoring capability
4Measurement precision
If physical separation methods are used, then size distribution is determined, but process interruption occurs
Solution Approach 1:
The patent replaces physical separation methods with optical measurement, allowing size distribution analysis without stopping the production line. The optical system measures particles in their natural state within the mixture, eliminating the need to interrupt production for sampling and physical separation
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
Facilitates faster, more accurate, and more frequent determination of size distribution parameters, enhancing process control and error detection, particularly for small particles, thus improving product quality and efficiency.
Implementation Method 1
A. Creating at least one image of the mixture with an optical system
Implementation Method 2
B. Transmitting the at least one image to an evaluation device and generating at least one output characteristic curve from the at least one image, wherein the at least one output characteristic curve is formed by a mathematical transformation of the at least one image, preferably by a Fourier transform
Data Source
Figure 1~2
AI summary
The invention relates to a method for determining at least one parameter of a size distribution of a mixture (10, 10') of particles during the manufacture of material boards(12), said method comprising the steps of: A. Producing at least one image of the mixture (10, 10') using an optical system (17); B. Transmitting the at least one image to an evaluation device (14) and generating at least one output characteristic from the at least one image, the at least one output characteristic being formed using a mathematical transformation of the at least one image, preferably using a Fourier transform, and representing a profile of an intensity, preferably a normalised intensity, over a spatial frequency; C. Determining at least one approximation characteristic in the evaluation device (14) by means of approximation in such a way that the at least one approximation characteristic substantially coincides with the at least one output characteristic, or at least substantially coincides in certain regions, the at least one approximation characteristic being based on or dependent at least on a geometry of the particles; and D. Determining the at least one parameter of the size distribution of the mixture (10) based on the at least one approximation characteristic and/or output characteristic. The invention also relates to: a device (13) for determining at least one parameter of a size distribution of a mixture (10, 10') of particles; a plant (1) for manufacturing material boards (12); and a computer programme product.