Tempering Machine Control for Casting Mass Supply Stability
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Solution Overview
Problem
Existing systems for producing cast products, such as confectionery items, face energy inefficiencies and interruptions in casting compound supply due to fluctuations in storage container filling levels, particularly when using pre-crystallizers, leading to unnecessary seed mass consumption and potential production interruptions.
Innovation Solution
Implementing a control system that regulates the tempering machine's output based on the current and anticipated consumption of casting compound by the casting machine, proactively adjusting the supply to match dynamic consumption patterns, thereby reducing response times and preventing extreme filling level fluctuations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the casting compound is cyclically fed through the tempering machine based on filling level monitoring, then the storage container filling level can be maintained, but energy consumption increases and seed mass is wasted
Solution Approach 1:
The system performs preliminary action by proactively filling the storage container when consumption is low, rather than reactively cycling the tempering machine when the container is low. The method anticipates future consumption patterns and adjusts tempering machine operation accordingly, maintaining filling levels through planned rather than emergency refilling, thus avoiding unnecessary energy consumption and seed mass usage.
Solution Approach 2:
The system implements feedback by continuously monitoring both the storage container filling level and the actual consumption of casting compound by the casting machine. This dual feedback mechanism allows the control system to adjust the tempering machine operation based on real-time consumption data, preventing both overfilling and underfilling, and optimizing energy usage by operating the tempering machine only when actually needed.
2Reliability
If the casting compound is cyclically fed through the pre-crystallizer, then the storage container filling level can be maintained, but the degree of pre-crystallization deteriorates and seed mass consumption increases
Solution Approach 1:
The system performs preliminary action by maintaining the casting compound in the pre-crystallizer only when needed, based on predicted consumption patterns. Instead of continuous or cyclic processing that degrades crystallization quality, the system proactively prepares the required amount of pre-crystallized compound and maintains it in optimal conditions, preventing degradation through unnecessary reprocessing.
Solution Approach 2:
The system implements feedback by monitoring both the storage container filling level and the actual consumption rate. This allows the control system to adjust the pre-crystallizer operation precisely, feeding compound through the pre-crystallizer only when consumption indicates a need for refilling, thereby maintaining the degree of pre-crystallization and reducing seed mass consumption while still ensuring reliable filling level maintenance.
3Reliability
If the tempering machine operates continuously to maintain filling level, then supply interruptions are prevented, but energy consumption and seed mass usage increase
Solution Approach 1:
The system performs preliminary action by anticipating future consumption needs based on current consumption rates and proactively filling the storage container before it runs low. This allows the tempering machine to operate intermittently rather than continuously, preventing supply interruptions through planned refilling while minimizing seed mass consumption by avoiding unnecessary tempering machine operation when the container is adequately filled.
Solution Approach 2:
The system implements feedback by continuously monitoring the storage container filling level and the actual consumption rate by the casting machine. This real-time feedback enables the control system to optimize the timing and duration of tempering machine operation, ensuring supply continuity by refilling only when necessary and operating the tempering machine at minimal capacity during refilling, thus reducing seed mass consumption while maintaining reliable supply.
4Reliability
If the filling level is monitored and tempering machine is cycled accordingly, then storage container can be kept filled, but extreme fluctuations and supply interruptions still occur
Solution Approach 1:
The system performs preliminary action by using consumption rate data to predict when the storage container will need refilling and initiating the refilling process proactively. Instead of waiting for the filling level to drop to critical thresholds that cause fluctuations, the system anticipates the need and refills in advance, smoothing out filling level variations and preventing supply interruptions before they can occur.
Solution Approach 2:
The system implements feedback by monitoring both the storage container filling level and the consumption rate by the casting machine. This dual feedback allows the control system to detect changes in consumption patterns and adjust the tempering machine operation accordingly, maintaining a more stable filling level by refilling at optimal moments rather than reacting to extreme level changes, thus preventing supply interruptions and maintaining production continuity.
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 allows for more cost-effective operation by minimizing energy use and avoiding interruptions in casting compound supply, enabling fully continuous production with reduced cocoa butter consumption and overproduction, thus enhancing system efficiency and stability.
Implementation Method 1
Pre-crystallizers are often used instead of a comparatively simple tempering machine, which is able to pre-crystallize the casting mass through controlled cooling and heating.
Implementation Method 2
Pre-crystallizers are often used instead of a comparatively simple tempering machine, which is able to pre-crystallize the casting mass through controlled cooling and heating.
Implementation Method 3
Pre-crystallizers are often used instead of a comparatively simple tempering machine, which is able to pre-crystallize the casting mass through controlled cooling and heating.
Data Source
Figure 1A~2
Figure 3~4b
Figure 5
AI summary
Operating a plant (1) for producing casting product (2) from a casting mass (3), comprising at least the components including a tempering machine (4) for at least parts of the casting mass, a reservoir (5), a casting machine and a device in product flow direction, comprises supplying at least parts of the casting mass from the tempering machine to the reservoir, where the supply of the casting mass is carried out depending on at least one control- or regulating signal, which is based on the current and/or anticipated consumption of casting mass by casting machine and/or casting plant. Operating a plant (1) for producing casting product (2) from a casting mass (3), comprising at least the components including a tempering machine (4) for at least parts of the casting mass, a reservoir (5) for the casting mass, a casting machine for the casting mass, and a device for further processing of casting product in product flow direction, comprises supplying at least parts of the casting mass from the tempering machine to the reservoir, where the supply of the casting mass is carried out depending on at least one control- or regulating signal, which is based on the current and/or anticipated consumption of casting mass by the casting machine and/or the casting plant. Independent claims are also included for: (1) a plant for producing casting product from the casting mass; (2) a computer program product comprising a computer readable medium with machine readable code, which is connected with a plant through a computer for producing the casting products from the casting mass, preferably a plant, which is operated by the above mentioned method; and (3) rebuilding the plant, comprising upgrading the plant based on the control- or regulating signal.