Segmented Weighing and Mixing System for Plastic Masterbatch Color Accuracy
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Solution Overview
Problem
Current feeder systems in the plastic industry lack the high degree of accuracy required to produce desired shades of plastic products using color masterbatches, as they cannot accurately weigh and mix granules to less than 0.03 grams, leading to inconsistencies in color and product quality.
Innovation Solution
A modular weighing and mixing system with parallel weighing chambers and a feeding mechanism using an auger, screw, conveyor belt, or dosing cylinder, controlled by a computer to achieve precise weight measurements, allowing for the combination of masterbatches and additives to be fed into processing machines with high accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional feeder systems are used to feed masterbatches and additives, then the system is simple and easy to operate, but the weighing accuracy cannot achieve less than 0.03 grams
Solution Approach 1:
The system divides the feeding process into multiple sequential stages: a first feeding system dispenses the majority of material (e.g., 90-99% of target weight), followed by a second feeding system that adds the remaining small amount (e.g., 1-10% of target weight). This segmentation allows each stage to be optimized for its specific function, achieving high precision for small quantities while maintaining overall system efficiency.
Solution Approach 2:
The first feeding system performs preliminary dispensing of the bulk material before the second feeding system adds the precise final amount. This preliminary action removes the majority of material first, making the subsequent precision measurement and addition of small quantities more accurate and reliable.
2Manufacturing precision
If a single feeding system is used to dispense all material, then the device structure is simple, but the accuracy for small quantity additions is insufficient
Solution Approach 1:
The feeding system is segmented into at least two independent feeding systems: a first feeding system for bulk material dispensing and a second feeding system for precise small-quantity addition. This segmentation enables each subsystem to be optimized for its specific range, with the second system专门 designed for high-precision small quantity control.
Solution Approach 2:
The first feeding system deliberately dispenses slightly less than the total required amount (leaving a small deficit), which is then precisely made up by the second feeding system. This partial action approach ensures that the critical precision requirement is applied only where needed, rather than requiring the entire system to operate at maximum precision.
3Stability of the object's composition
If conventional gravimetric blenders are used to mix components, then the system is simple and fast, but the color uniformity and homogeneity of masterbatches cannot be achieved
Solution Approach 1:
The mixing system is divided into multiple independent mixing chambers rather than a single blending chamber. Each chamber receives precisely measured portions of masterbatches and additives from the segmented feeding systems, ensuring that each component is thoroughly mixed in its designated chamber before final combination, thereby achieving superior homogeneity.
Solution Approach 2:
Components undergo preliminary mixing in separate chambers before final combination. This preliminary action ensures that each masterbatch and additive is uniformly distributed within its respective chamber, creating homogeneous sub-mixes that combine to form a uniformly colored final product.
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 achieves an accuracy of less than 0.03 grams per component, enabling the production of uniform masterbatches and pellets with precise color shades, reducing inventory needs and costs for manufacturers while providing faster and more affordable color options to customers.
Implementation Method 1
a weighing chamber (10) comprising a weighing device (32)
Implementation Method 2
a feeding mechanism (25) with an auger, screw, conveyor belt, or dosing cylinder
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
Weighing and mixing system (100) for the preparation of mixtures of components required by processing machines for the manufacture of plastic products. In particular, the system is suitable for the preparation of weighed mixtures comprised of at least two different masterbatches in order to obtain the color shade desired for a specific plastic product. Also disclosed is a related method of producing a homogeneous masterbatch using said system.