Powder Mixing System with Image-Based Homogeneity Detection
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Solution Overview
Problem
Existing powder mixing systems are inefficient, requiring excessive time to achieve homogeneous mixing due to the need for manual evaluation of powder homogeneity, leading to low productivity in final product manufacturing.
Innovation Solution
A powder mixing system incorporating a rotating mixing vessel, an image photographing device, and a computer that estimates the mixing state based on acquired images, allowing for real-time monitoring and termination of the mixing process when a predetermined mixing degree is reached, thereby reducing overall mixing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual extraction and evaluation of powder homogeneity is performed, then measurement precision of mixing state is improved, but mixing time increases significantly
Solution Approach 1:
The patent replaces manual mechanical extraction and visual evaluation with an automated image photographing device that captures images of powder inside the mixing vessel through a window. The computer then automatically analyzes these images to estimate mixing state, eliminating the need for manual powder extraction while maintaining evaluation accuracy.
Solution Approach 2:
The patent creates an optical copy (image) of the powder mixture inside the mixing vessel instead of physically extracting powder for analysis. The image photographing device captures visual information that represents the mixing state, allowing the computer to evaluate homogeneity without disturbing the mixing process or requiring manual intervention.
2Productivity
If continuous monitoring of mixing process is implemented, then productivity is improved, but device complexity increases
Solution Approach 1:
The computer in the patent serves multiple functions: it controls the mixing process, captures images through the image photographing device, analyzes powder homogeneity, and determines when mixing is complete. This multi-functionality reduces the need for separate dedicated devices for each function, thereby limiting the increase in overall system complexity while achieving continuous monitoring.
Solution Approach 2:
The system performs self-monitoring and self-evaluation of the mixing process. The image photographing device automatically captures images, the computer analyzes them to estimate mixing state, and the system can autonomously determine when mixing is complete without requiring external manual evaluation or complex control systems.
3Loss of time
If real-time image acquisition is performed, then mixing time is reduced, but measurement precision requirements increase
Solution Approach 1:
The patent changes the parameter of image acquisition timing to match the mixing process dynamics. By acquiring images at specific moments during mixing (rather than continuously or manually at the end), the system captures mixing state information that enables accurate homogeneity estimation while minimizing total mixing time. The computer analyzes these timed images to determine when mixing objectives are met.
Data Source
AI summary
A powder mixing system and method improves productivity of a final product by reducing time required for completion of mixing. The powder mixing system includes a mixing vessel provided with a rotating shaft for mixing multiple kinds of powder, a rotating machine for rotating the mixing vessel by means of the rotating shaft, an image photographing device for acquiring an image of the powder in a mixing process, and a computer. The mixing vessel includes a window through which the image of the powder is photographed. The computer has a function of detecting that the mixing vessel is located at a predetermined position. The image photographing device acquires the image of the powder through the window of the mixing vessel located at the predetermined position. The computer estimates a mixing state of the powder based on the acquired image of the powder.