Variable Stroke Mixing Shaft for Settled Powder
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Solution Overview
Problem
Biotech companies face challenges in mixing powdered biological materials due to settling issues, which can damage equipment and increase costs, as traditional mixing methods like shaking are inefficient and risky for large containers.
Innovation Solution
A mixing system with a variable stroke length mechanism, utilizing a linear or servo motor to adjust the mixing shaft's length, reduces stress on the equipment and improves mixing efficiency by adapting to settlement thickness, thereby minimizing damage and increasing container size flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional shaking method is used to mix powdered base materials, then mixing is achieved, but stress on the mixing equipment increases and disposable tank liners are at risk
Solution Approach 1:
A flexible mixing element is introduced as an intermediary between the mixing shaft and the settled powdered material. This flexible element adapts to the settled material configuration, breaking it up without transmitting excessive stress to the tank liner or mixing equipment, thereby resolving the contradiction between mixing effectiveness and equipment protection
Solution Approach 2:
The mixing system employs a flexible mixing element that dynamically adapts its shape and movement according to the settled material distribution. This dynamic behavior allows effective mixing while automatically adjusting to avoid excessive stress on equipment and tank liners
2Loss of energy
If powdered base materials are shipped and stored in powdered form to decrease costs, then storage and transport costs are reduced, but the materials become difficult to mix and can damage mixing equipment
Solution Approach 1:
The flexible mixing element serves as a mediator between the settled powdered material and the mixing shaft, enabling effective breakup and mixing of concentrated powder without transmitting damaging forces to the equipment, thus resolving the manufacturing difficulty while maintaining the cost benefits of powdered storage
Solution Approach 2:
The system changes the mixing approach by using a flexible element with varying stiffness characteristics that can effectively handle settled powdered material, transforming the mixing process to accommodate the challenges of powdered form storage and transport
3Stability of the object's composition
If the mixing container is shaken to break up concentrated powdered materials, then mixing is improved, but the size of the mixing container is limited and disposable tank liners are at risk
Solution Approach 1:
The flexible mixing element acts as an intermediary that achieves material homogeneity through adaptive movement and contact with settled powder, eliminating the need for container shaking and enabling use of larger containers without compromising liner safety or mixing effectiveness
Solution Approach 2:
Instead of shaking the entire container to achieve mixing, the invention inverts the approach by using a flexible mixing element that actively adapts to and breaks up settled material from the mixing shaft, achieving homogeneity without container-level vibration and enabling larger container sizes
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 effectively breaks up settled powdered materials, reduces stress on equipment, increases the lifespan of mixing assemblies, and decreases risks to disposable liners, while allowing for larger container sizes and more efficient mixing processes.
Implementation Method 1
a linear motor, and a shaft having a first end secured to the mixer and an opposing second end secured to the linear motor. The linear motor provides a variable stroke length for the shaft
Implementation Method 2
a servo motor, a shaft having a first end secured to the mixer and an opposing second end extending from the container and secured to the servo motor, and a sensor to measure a thickness of a settlement within the container. A stroke length of the servo motor is configured to vary in length in response to measurements from the sensor
Data Source
AI summary
A mixing system includes a tank assembly and a container positioned within the tank assembly, the container bounding a compartment. A mixer is disposed within the compartment of the container. A shaft has a first end secured to the mixer and an opposing second end disposed outside of the container. An actuation mechanism is coupled with the second end of the shaft outside of the container and reciprocally moves the shaft and the mixer a stroke length, the stroke length being adjusted based on a pre-programmed protocol or signals from a sensor.