Optical-Sensor Recirculation Batching with Robotic Dispensing
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Solution Overview
Problem
Current batching processes for mixing solids and/or liquids are space and time-intensive, requiring substantial human movement and are prone to errors, leading to inefficiency and waste.
Innovation Solution
A batching system comprising a vessel, mixer, pump, and optical sensor connected by piping, allowing materials to re-circulate until fully mixed, with automated control and dispensing using an articulated or robotic arm, and incorporating a clean-in-place subsystem.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional manual batching process is used, then flexibility in material handling is maintained, but space requirements and time consumption increase significantly
Solution Approach 1:
The patent replaces manual mechanical handling with an automated robotic system. A robotic arm equipped with sensors and control systems automatically retrieves raw materials from storage locations, transports them to the mixing station, and performs batching operations without human intervention, thereby reducing process time while maintaining operational flexibility through programmable control.
Solution Approach 2:
The system enables self-service automation where the robotic batching system operates autonomously based on pre-programmed instructions. The system can automatically retrieve materials, measure quantities, transfer to mixers, and clean equipment without requiring continuous human oversight, reducing both time consumption and labor requirements.
2Adaptability or versatility
If traditional manual batching process is used, then adaptability to different materials is maintained, but human error and waste increase
Solution Approach 1:
The patent incorporates sensors and control systems that provide real-time feedback during the batching process. Optical sensors, weight sensors, and other detection devices monitor material properties, quantities, and mixing conditions, automatically adjusting parameters to maintain quality standards and prevent errors, thereby improving reliability while preserving adaptability through programmable control.
Solution Approach 2:
By replacing manual operations with automated robotic systems equipped with sensors and control algorithms, the system eliminates human error while maintaining material handling adaptability through programmable instructions that can be adjusted for different material types and batch requirements.
3Productivity
If automated robotic batching system is implemented, then productivity and precision are improved, but device complexity increases
Solution Approach 1:
The patent employs a multi-functional robotic system that can perform multiple operations including material retrieval, weighing, transferring, mixing, and cleaning with a single integrated platform. This universal system handles different material types and batch sizes through programmable control, improving productivity while managing complexity through consolidation of functions into one versatile apparatus.
4Ease of operation
If traditional multi-station process is used, then operational flexibility is maintained, but movement requirements and space increase
Solution Approach 1:
The patent merges multiple separate batching stations into a single integrated robotic system. The robotic arm can access material storage, weighing stations, and mixing equipment within one compact workspace, eliminating the need for separate physical stations and reducing factory floor space requirements while maintaining operational flexibility through automated sequencing.
Solution Approach 2:
The system transitions from a horizontal layout with multiple分散 stations to a vertical or compact three-dimensional workspace where the robotic arm operates within a confined space, accessing materials and equipment from multiple directions, thereby reducing the footprint while maintaining operational capabilities.
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 system significantly reduces space and movement requirements, enhances efficiency, minimizes errors, and reduces waste by automating the batching process while ensuring high-quality mixing and cleaning.
Implementation Method 1
an optical sensor coupled to the piping... until at least one reading from the optical sensor indicates that the materials are fully mixed
Implementation Method 2
a pump coupled to the piping... circulating the materials through a mixer, a pump
Data Source
AI summary
A batching system involves a vessel, a mixer, a pump, and an optical sensor, wherein the vessel, the mixer, the pump and the optical sensor are coupled together by piping so as to form a circuit within which materials will re-circulate while being mixed by the mixer until at least one reading from the optical sensor indicates that the materials are fully mixed. An associated batching method involves introducing into a vessel, via gravity feed through mass flow meters, multiple materials to be mixed, repeatedly circulating the materials through a mixer, a pump, a spectroscope and the vessel until a reading from the optical sensor indicates that the multiple materials are fully mixed, and once the multiple materials are fully mixed, dispensing the fully mixed materials into at least one package container using an articulated arm.