Vibration-Based Masterbatch Feeding System for Precision Weighing
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Solution Overview
Problem
Existing systems for weighing and feeding small quantities of masterbatch materials, such as those used in plastic production, face accuracy issues due to variations in specific gravity from supplier to supplier, requiring frequent recalibration and skilled labor, especially when using volumetric methods.
Innovation Solution
A weighing and feeding system utilizing a load cell, vibration unit, and controller to implement the loss-in-weight method, allowing for precise measurement and adjustment of masterbatch dispensing through controlled amplitude and frequency of vibrations, enabling accurate delivery of small pellet quantities to processing machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If volumetric feeding methods are used to feed small quantities of masterbatch, then the feeding speed is improved, but the weighing precision deteriorates due to specific gravity variations
Solution Approach 1:
The patent replaces the mechanical volumetric feeding system with a vibration-based feeding system combined with loss-in-weight measurement. The vibration unit causes pellets to move through an outlet channel while load cells continuously measure the hopper weight, substituting mechanical volume-based dosing with a system that uses vibration control and direct weight measurement for precise feeding.
2Measurement precision
If screw feeders with loss-in-weight method are used for small quantities of material, then the weighing precision is improved, but the feeding reliability deteriorates
Solution Approach 1:
The patent applies mechanical vibration through a vibration unit that causes pellets to move through an outlet channel. The vibration frequency and amplitude are controlled to ensure reliable flow of material while maintaining precise weight measurement through the loss-in-weight method, solving the reliability issue of screw feeders for small quantities.
3Measurement precision
If frequent recalibration is performed to maintain accuracy with different suppliers, then the measurement precision is maintained, but the loss of time increases
Solution Approach 1:
The system performs automatic calibration by measuring the weight of a known volume of material and using this information to adjust the vibration parameters. This self-calibrating capability eliminates the need for manual recalibration with skilled workers, maintaining accuracy across different suppliers and batches without time loss.
4Measurement precision
If skilled workers perform calibration to ensure accuracy, then the measurement precision is improved, but the device complexity increases
Solution Approach 1:
The system automatically performs calibration by measuring material weight and adjusting vibration parameters without human intervention. The controller automatically processes the calibration data and adjusts the feeding system, eliminating the need for skilled workers and simplifying the overall process complexity.
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 ensures accurate and reliable weighing and feeding of small masterbatch quantities, reducing the need for frequent recalibration and skilled labor, and maintaining precision across different production batches and suppliers.
Implementation Method 1
a load cell (26) which weighs the hopper (22) and material
Implementation Method 2
measuring the weight of the hopper and material with the load cell
Implementation Method 3
a vibration unit (30) causing the tray (24) to vibrate at a constant frequency
Implementation Method 4
The amplitude of the vibrations can be changed, thereby increasing or decreasing the flow rate of masterbatch
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
The invention is a weighing and feeding system for accurate weighing of small quantities of material in pelletized form and feeding the weighed material to processing machines. In particular the invention, is suitable for the preparation of weighed quantities of masterbatch to be added with resin directly into injection molding or extrusion machines for the manufacture of plastic products.