Powder Dispenser Modules with Sensor Feedback for Cohesive Powders
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Solution Overview
Problem
Existing manufacturing techniques and equipment are inadequate for efficiently and accurately dispensing precise quantities of cohesive powders, such as drug powders for inhalers, into multiple cartridges, requiring improved methods and apparatus for high-throughput production with minimal floor space.
Innovation Solution
A powder dispensing and sensing apparatus comprising a powder dispenser module with a housing, feed wand, valve, and sensor module, which allows for precise control of powder dispensing into cartridges based on sensed fill states, enabling accurate and efficient filling of multiple cartridges simultaneously.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If existing manufacturing techniques are used to dispense powder into multiple cartridges, then production throughput can be maintained, but manufacturing precision and accuracy of powder dosing deteriorate
Solution Approach 1:
The system divides the powder dispensing process into multiple independent dispenser modules, each capable of precisely controlling powder delivery to individual cartridges. This segmentation allows parallel processing of multiple cartridges simultaneously while maintaining high precision dosing control in each module
Solution Approach 2:
The system incorporates sensor cells that provide real-time feedback on powder fill state to controller circuits in each dispenser module. This feedback mechanism enables dynamic adjustment of dispensing parameters to achieve target powder weights with high precision while maintaining efficient production throughput
2Manufacturing precision
If existing equipment is used to handle cohesive powders, then equipment simplicity is maintained, but manufacturing precision and handling capability deteriorate
Solution Approach 1:
The system employs pneumatic mechanisms including air flow through nozzles and pressure-controlled valve assemblies to manage cohesive powder flow. These pneumatic systems provide precise control over powder delivery while managing the challenges of handling cohesive materials
Solution Approach 2:
The dispenser modules incorporate dynamically adjustable parameters including variable dispensing speed, real-time weight feedback control, and adaptive valve timing. These dynamic adjustments enable high-precision dosing of cohesive powders by responding to real-time conditions during the dispensing process
3Productivity
If high-speed powder dispensing is implemented, then productivity is improved, but manufacturing precision and dose accuracy deteriorate
Solution Approach 1:
The system maintains continuous operation through parallel dispenser modules working simultaneously on multiple cartridges. Each module operates continuously at high speed while the sensor-cell-controller feedback loop continuously monitors and adjusts powder delivery to maintain precision throughout the dispensing process
Solution Approach 2:
Real-time weight sensing through sensor cells provides continuous feedback to controller circuits, enabling dynamic adjustment of dispensing parameters at high speed. This feedback mechanism ensures dose accuracy is maintained even during rapid dispensing operations
4Area of stationary object
If compact dispenser modules are used to reduce floor space, then area requirements are reduced, but device complexity and handling capability worsen
Solution Approach 1:
The system integrates multiple functions including powder storage, metering, valve control, weight sensing, and digital control into single compact dispenser modules. This merging of functions reduces the overall footprint while managing complexity through modular design where each module is a self-contained unit
Solution Approach 2:
The dispenser modules are designed with nested components where the feed wand assembly fits within the housing, sensor cells are integrated into the cartridge support structure, and multiple modules can be arranged in compact arrays. This nesting approach minimizes floor space requirements while maintaining functional capabilities
Data Source
AI summary
A powder dispenser module (54) includes a housing (150) that defines a conduit connecting a powder inlet and a powder outlet, a feed wand (160) to move powder through the conduit from the powder inlet to the powder outlet, the feed wand (200) including a lower feed element (230) coupled to a first drive shaft and an upper feed element (220) coupled to a second drive shaft, a first actuator coupled to the first drive shaft to rotate the lower feed element (230), and a second actuator coupled to the second drive shaft to rotate the upper feed element (220). In other embodiments, the feed wand (200) includes a shaft having a fluidizing element and an actuator produces oscillatory movement of the feed wand during dispensing of powder. Dispenser module arrays include one or a few rows of dispenser modules.