Molded product production system

• US 10,449,701 B2
• Filed: 02/01/2017
• Issued: 10/22/2019
• Est. Priority Date: 03/29/2016
• Status: Active Grant

• Current Assignee: Kikusui Seisakusyo Limited
• Original Assignee: Kikusui Seisakusyo Limited
• Inventors: Kitamura, Naoshige, Oyama, Jun
• Primary Examiner(s): Calandra, Anthony
• Assistant Examiner(s): Nelson, Jamel M
• Application Number:
  US15/422,306
• Publication Number:
  US 20170282421A1
• Time in Patent Office: 993 Days
• CPC Class Codes: B01F 2101/22 Mixing of ingredients for pharmaceutical or medical compositions
• CPC Class Codes: B01F 23/60 Mixing solids with solids
• CPC Class Codes: B01F 27/0723 oblique with respect to the rotating axis
• CPC Class Codes: B01F 27/0726 having stirring elements connected to the stirrer shaft each by a single radial rod, other than open frameworks
• CPC Class Codes: B01F 27/1123 sickle-shaped, i.e. curved in at least one direction
• CPC Class Codes: B01F 27/11253 the blades extending oblique to the stirrer axis
• CPC Class Codes: B01F 27/191 with similar elements
• CPC Class Codes: B01F 27/70 with paddles, blades or arms
• CPC Class Codes: B01F 27/906 with fixed axis
• CPC Class Codes: B01F 33/821 with consecutive receptacles
• CPC Class Codes: B01F 35/213 of the properties of the mixtures, e.g. temperature, density or colour
• CPC Class Codes: B01F 35/2144 using radiation for measuring the parameters of the mixture or components to be mixed
• CPC Class Codes: B01F 35/2202 Controlling the mixing process by feed-back, i.e. a measured parameter of the mixture is measured, compared with the set-value and the feed values are corrected
• CPC Class Codes: B01F 35/2209 Controlling the mixing process as a whole, i.e. involving a complete monitoring and controlling of the mixing process during the whole mixing cycle
• CPC Class Codes: B01F 35/82 by adding a material to be mixed to a mixture in response to a detected feature, e.g. density, radioactivity, consumed power or colour
• CPC Class Codes: B29B 7/44 with paddles or arms
• CPC Class Codes: B29B 7/726 Measuring properties of mixture, e.g. temperature or density B29B7/724 takes precedence
• CPC Class Codes: B29B 7/80 Component parts, details or accessories; Auxiliary operations B29B7/22, B29B7/58 take precedence ; cleaning mixers B01F35/145
• CPC Class Codes: B29C 2043/585 detecting defects, e.g. foreign matter between the moulds, inaccurate position, breakage
• CPC Class Codes: B29C 2043/5875 the material feed to the moulds or mould parts, e.g. controlling feed flow, velocity, weight, doses
• CPC Class Codes: B29C 43/02 : of articles of definite length, i.e. discrete articles B29C35/0227 takes precedence
• CPC Class Codes: B29C 43/34 : Feeding the material to the mould or the compression means B29C43/085 takes precedence
• CPC Class Codes: B29C 43/58 : Measuring, controlling or regulating for bank adjustment in calendering B29C43/245
• CPC Class Codes: B29K 2105/251 : Particles, powder or granules expandable particles B29K2105/046
• CPC Class Codes: B30B 11/08 : co-operating with moulds carried by a turntable
• CPC Class Codes: B30B 15/0011 : lubricating means
• CPC Class Codes: B30B 15/302 : Feeding material in particulate or plastic state to moulding presses

Abstract

A molded product production system includes at least two measuring feeders configured to simultaneously adjust an amount of a discharged powdery material to a target value and feed the powdery material, a mixer configured to mix at least two powdery materials fed from the measuring feeders to obtain mixed powdery materials, a filler configured to fill, with the mixed powdery materials obtained by the mixer, a die bore of a compression-molding machine configured to compress a powdery material to mold a molded product, a sensor configured to measure a mixing degree of the mixed powdery materials obtained by the mixer, and a controller configured to adjust an amount of at least one of the powdery materials fed by the measuring feeders, or motion speed of a mixing member configured to agitate powdery materials in the mixer in accordance with the mixing degree of the mixed powdery materials measured by the sensor.

Claims

1. A molded product production system, comprising:

at least two measuring feeders configured to simultaneously adjust an amount of a discharged powdery material to a target value and feed the powdery material;

a mixer configured to mix at least two powdery materials fed from the measuring feeders to obtain mixed powdery materials;

a filler configured to fill, with the mixed powdery materials obtained by the mixer, a die bore of a compression-molding machine configured to compress a powdery material to mold a molded product;

a sensor configured to measure a mixing degree of the mixed powdery materials obtained by the mixer; and

a controller configured to, depending upon an absolute value of a difference between a target value and the mixed degree of the mixed powdery materials measured continuously for at least a certain period by the sensor relative to a predetermined threshold, adjust an amount of at least one of the powdery materials fed by the measuring feeders, or a motion speed of a mixing member configured to agitate powdery materials in the mixer, in accordance with the mixing degree of the mixed powdery materials measured by the sensor.

2. The molded product production system according to claim 1, wherein the controller controls to change the amount of at least one of the powdery materials fed by the measuring feeders when the absolute value of the difference between the target value and the mixing degree of the mixed powdery materials measured by the sensor is more than the predetermined threshold continuously for at least the certain period.

3. The molded product production system according to claim 1, wherein the controller controls to change the motion speed of the mixing member configured to agitate powdery materials in the mixer when the absolute value of the difference between the target value and the mixing degree of the mixed powdery materials measured by the sensor is not more than the predetermined threshold continuously for at least the certain period, and is more than the threshold instantaneously or for a period shorter than the certain period.

4. The molded product production system according to claim 1, wherein the controller adjusts the amount of at least one of the powdery materials fed by the measuring feeders or the motion speed of the mixing member configured to agitate powdery materials in the mixer, and further adjusts a rotational speed of a turret including the die bore and a punch configured to compress a powdery material filled in the die bore in the compression-molding machine.

5. The molded product production system according to claim 2, wherein the controller controls to change the motion speed of the mixing member configured to agitate powdery materials in the mixer when the absolute value of the difference between the target value and the mixing degree of the mixed powdery materials measured by the sensor is not more than the predetermined threshold continuously for at least the certain period, and is more than the threshold instantaneously or for a period shorter than the certain period.

6. The molded product production system according to claim 2, wherein the controller adjusts the amount of at least one of the powdery materials fed by the measuring feeders or the motion speed of the mixing member configured to agitate powdery materials in the mixer, and further adjusts a rotational speed of a turret including the die bore and a punch configured to compress a powdery material filled in the die bore in the compression-molding machine.

7. The molded product production system according to claim 3, wherein the controller adjusts the amount of at least one of the powdery materials fed by the measuring feeders or the motion speed of the mixing member configured to agitate powdery materials in the mixer, and further adjusts a rotational speed of a turret including the die bore and a punch configured to compress a powdery material filled in the die bore in the compression-molding machine.

8. The molded product production system according to claim 1, wherein the controller controls to change the motion speed of the mixing member configured to agitate powdery materials in the mixer when the absolute value of the difference between the target value and the mixing degree of the mixed powdery materials measured by the sensor is not more than the predetermined threshold continuously for at least the certain period.

9. The molded product production system according to claim 1, wherein the controller adjusts the amount of at least one of the powdery materials fed by the measuring feeders, and further adjusts a rotational speed of a turret including the die bore and a punch configured to compress a powdery material filled in the die bore in the compression-molding machine.

10. The molded product production system according to claim 1, wherein the controller adjusts the amount of at least one of the powdery materials fed by the motion speed of the mixing member configured to agitate powdery materials in the mixer, and adjusts a rotational speed of a turret including the die bore and a punch configured to compress a powdery material filled in the die bore in the compression-molding machine.

11. The molded product production system according to claim 1, wherein the controller adjusts a rotational speed of a turret including the die bore and a punch configured to compress a powdery material filled in the die bore in the compression-molding machine.

12. The molded product production system according to claim 1, further comprising:

a buffer tank, placed between the mixer and the compression-molding machine, for temporarily reserving the mixed powdery materials.

13. The molded product production system according to claim 12, wherein the sensor comprises a first infrared sensor configured to measure the mixing degree of the mixed powdery materials before being reserved in the buffer tank.

14. The molded product production system according to claim 13, wherein the sensor further comprises a second infrared sensor configured to measure the mixing degree of the mixed powdery materials after being reserved in the buffer tank.

15. The molded product production system according to claim 1, wherein the sensor measures the mixing degree of the mixed powdery materials by one of Raman spectroscopy, infrared spectroscopy, X-ray diffraction, X-ray transmission measurement, and high performance liquid chromatography (HPLC).

16. The molded product production system according to claim 1, wherein the sensor measures the mixing degree of the mixed powdery materials based on an absorption peak of a principal agent in the mixed powdery materials.

17. The molded product production system according to claim 1, wherein the sensor measures the mixing degree of the mixed powdery materials based on a uniformity of the mixed powdery materials.

18. The molded product production system according to claim 1, wherein the mixer comprises:

a vertical mixer that is fed from the measuring feeders; and

a horizontal mixer that is located between the vertical mixer and the filler.

19. The molded product production system according to claim 18, wherein the sensor measures the mixing degree of the mixed powdery materials after the mixed powdery materials exit from the horizontal mixer.

20. The molded product production system according to claim 1, further comprising:

a buffer tank, placed between the mixer and the filler, for temporarily reserving the mixed powdery materials,

wherein the sensor measures the mixing degree of the mixed powdery materials at following locations;

before the mixed powdery materials enter the buffer tank;

after the mixed powdery materials exit the buffer tank and before the mixed powdery materials enter the filler; and

in the filler.