Rotary Press Fill Level Control for Food Tablet Weight Variation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing rotary presses for compressing food materials into tablets, such as bouillon tablets, suffer from weight variation and hardness inconsistencies due to discontinuous feeding and reliance on sensor-based fill level adjustments, leading to crumbling or inadequate hardness issues.
Innovation Solution
A rotary press with a continuous feeding system and an analog sensor to maintain a precise fill level in the feeding pipe, allowing for continuous and controlled feeding speed adjustments to keep the fill level at a defined set point, independent of press system speed, using a single LED infrared sensor for accurate fill level detection and control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If discontinuous feeding with sensor-based fill level adjustment is used, then the feeding system is simple to operate, but the tablet weight variation increases to 0.15g
Solution Approach 1:
The patent replaces the mechanical/discontinuous feeding system with an analog sensor-based continuous monitoring system. The analog sensor continuously detects the fill level in the feeding pipe and provides continuous feedback to the control unit, enabling precise control of the feeding speed to maintain consistent tablet weight within ±0.05g variation.
Solution Approach 2:
The patent implements a feedback control system where the analog sensor continuously monitors the fill level in the feeding pipe and feeds this information back to the control unit. The control unit adjusts the feeding speed based on this feedback to maintain the fill level within the optimal range, ensuring consistent tablet weight and resolving the weight variation issue.
2Stability of the object's composition
If press system speed is adjusted to maintain fill level, then the fill level stability is improved, but the tablet hardness varies
Solution Approach 1:
The patent applies dynamics by making the feeding speed adjustable and variable based on real-time fill level conditions. The control unit dynamically adjusts the feeding speed within a range to maintain fill level stability while ensuring that the press system operates at optimal speeds for consistent tablet hardness, preventing the hardness variation caused by fixed speed adjustments.
Solution Approach 2:
The patent changes the parameter of feeding speed from a fixed value to a variable parameter that can be continuously adjusted within a defined range. The control unit modifies the feeding speed parameter based on analog sensor feedback to maintain fill level stability while preserving consistent tablet hardness characteristics.
3Device complexity
If digital sensor with discrete levels is used, then the control is simplified, but the fill level detection precision is insufficient
Solution Approach 1:
The patent replaces digital sensors with discrete measurement levels with an analog sensor that provides continuous fill level detection. This analog sensor outputs a continuous signal proportional to the fill level, providing superior measurement precision while the control unit processes this continuous information to adjust feeding speed, maintaining manageable control complexity.
Solution Approach 2:
The patent transitions from static discrete measurement levels to dynamic continuous measurement using an analog sensor. The analog sensor continuously tracks the fill level throughout the feeding pipe, providing real-time precise data that enables dynamic adjustment of feeding speed to maintain optimal fill level conditions.
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
This approach minimizes weight variation in food tablets to 0.05g per 10g, reducing variation by 66% and ensuring consistent hardness, enhancing production efficiency and tablet usability.
Implementation Method 1
analog sensor which is a LED infrared sensor
Data Source
Figure 1
AI summary
The present invention is directed to a rotary press (1) for compressing a pressing food material (M), like food powder, into food tablets (T), comprising a feeding system (2) comprising a feeder (20) for continuously supplying the pressing food material (M) and a feeding pipe (21) for providing the pressing food material (M) received from the feeder (20), a press system (3) comprising a rotary die plate (30) being drivable about a rotational axis (R) and comprising a plurality of die cavities (31) for successively receiving an amount of pressing food material (M) provided by the feeding pipe (21) and to produce food tablets (T) inside the die cavities (31) by means of punches (32) upon a rotational movement of the die cavities (31) of the rotary die plate (30) with respect to the feeding system (2), an analog sensor (4) for detecting a fill level (L) of the pressing food material (M) in the feeding pipe (21), and a control unit (5) configured to control a feeding speed of the feeder (20) for continuously supplying the pressing food material (M) based on the detected fill level (L) to keep the fill level (L) at a defined fill level set point (LSP). The present invention is further directed to a method for pressing a food tablet (T), like a bouillon cube, by compression of a pressing food material (M), like a food powder, with a rotary press (1).