Rotating Tablet Disk for Low-Waste Tablet Press Sensor Calibration
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Solution Overview
Problem
Existing tablet sensor calibration methods for tablet presses, particularly high-capacity rotary presses, are inefficient, costly, and complex, requiring large amounts of expensive product waste and manual adjustments due to dynamic measurement influences, leading to inaccurate data transfer.
Innovation Solution
A calibration device with a rotary calibration disk and tablet receptacles that simulate the tablet press environment, allowing precise measurement of pre-produced tablets with known properties, enabling flexible and cost-effective calibration by rotating the tablets through a stationary sensor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If calibration is performed in continuous production operation of the tablet press, then accurate calibration data can be obtained, but large amounts of expensive product waste and complex adjustments are required
Solution Approach 1:
The calibration process is segmented from continuous production by using a separate calibration device with a calibration disk that holds individual tablets. This allows calibration to be performed without requiring continuous production operation, thereby reducing product waste while maintaining calibration accuracy through controlled measurement conditions.
Solution Approach 2:
The calibration device creates a simplified copy of the tablet press measurement environment using a calibration disk with receptacles that simulate the die disk geometry. This copying approach allows accurate calibration data to be obtained without requiring actual production tablets or full production line operation, reducing both product waste and complexity.
2Measurement precision
If calibration is performed in continuous production operation, then dynamic measurement influences are captured, but considerable time and complex adjustments are required
Solution Approach 1:
Tablets are pre-positioned in the calibration disk receptacles before measurement begins. The calibration disk is then rotated to bring tablets into the measurement position, eliminating the need for time-consuming in-process adjustments during calibration. This preliminary arrangement of tablets reduces calibration time while maintaining measurement accuracy.
Solution Approach 2:
The calibration disk rotates to dynamically position tablets into the measurement field, simulating the dynamic measurement conditions of continuous production. This dynamic positioning mechanism allows accurate calibration data to be obtained without requiring prolonged static adjustment periods, thereby reducing calibration time while maintaining precision.
3Loss of substance
If static measurement of tablets is used, then product waste and adjustments are minimized, but dynamic measurement influences are not accounted for
Solution Approach 1:
The calibration disk rotates to dynamically position tablets through the measurement field, replicating the dynamic measurement conditions occurring during continuous production. This dynamic approach ensures that calibration data accurately reflects real production conditions while avoiding the need for large amounts of product waste and complex adjustments.
Solution Approach 2:
The system changes the measurement parameter from static to dynamic by rotating the calibration disk. This parameter change allows the measurement to capture dynamic influences such as tablet position and orientation variations that occur during production, thereby improving calibration accuracy without requiring product waste or complex adjustments.
4Measurement precision
If all production parameters are adjusted for new products, then accurate production data is obtained, but the process is complex and time-consuming
Solution Approach 1:
The calibration device extracts and isolates the critical measurement function from the complex production system. By using a simplified calibration disk with receptacles that simulate only the essential measurement geometry, the system obtains accurate calibration data without requiring adjustment of all production parameters, thereby reducing complexity while maintaining accuracy.
Solution Approach 2:
The calibration disk acts as an intermediary between the simple calibration process and the complex production system. It translates complex production conditions into a simplified measurable format, allowing accurate calibration data to be obtained without directly managing the complexity of production parameter adjustments.
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
Minimizes product waste and development costs while providing accurate calibration data, reducing the need for complex adjustments and early model creation, enhancing process safety and time-to-market.
Implementation Method 1
The tablet sensor disclosed in EP 1 568 480 B1 is a NIR or LIF sensor
Implementation Method 2
The tablet sensor disclosed in EP 1 568 480 B1 is a NIR or LIF sensor
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a calibration device wherein the calibration device comprises a tablet sensor configured to measure a content property of tablets, wherein the calibration device further comprises a calibration disk and a rotary drive for rotating the calibration disk about a rotational axis, wherein the calibration disk comprises a plurality of tablet receptacles, said tablet receptacles each configured to accommodate a pre-produced tablet with a known content property in a fixed position during rotation of the calibration disk, wherein the tablet sensor is arranged above the calibration disk such that tablets accommodated in the tablet receptacles rotate together with the calibration disk through a measuring field of the tablet sensor, wherein the tablet sensor obtains measuring data of a content property of the tablets in the measuring field, and wherein the calibration device further comprises a control device, said control device receiving the measuring data from the tablet sensor, and being configured to calibrate the tablet sensor on basis of the received measuring data and the known property contents of the tablets. The invention also relates to a corresponding method.