Mixer and a method of mixer control

Abstract: In a mixer comprising a body 1 defining a mixing chamber 2 in which two rotors 3 and 4 are rotatably mounted, a processability sensing system 9 is disposed in a port 8 in the body 1. The system is operative to monitor the flow and deformation characteristics of the material being mixed. It is connected to a feedback control loop which leads to a computerised control 11 operative to control mixing characteristics. This enables mixing to be closely controlled to provide a better product.

Description: The present invention relates to mixers and to a method of controlling mixers, according the pre-ambles of claims 1 and 13, respectively. The internal mixers presently used by the rubber industry are predominantly fixed-speed machines. However, the substantial reduction in the cost of variable speed drives in recent years has resulted in their installation with most recently purchased mixers. Conventional mixing control techniques are based on providing fixed or known amounts of kinetic and/or thermal energy during mixing. These techniques do not make provision for batch-to-batch variations in the internal energy and the entropy of the incoming material, with the result that any variations in these incoming properties, given that the material is subjected to constant processing conditions, will be reflected as batch-to-batch variations in the outgoing properties. These problems are particularly prevalent when mixing materials such as natural rubber. The Batch Condition Control (BCC) system has proposed a method of measuring, inter alia, the reaction torque experienced by the rotors of an internal mixer and, in terms of a known relationship between torque and viscosity, assessing the relative rheological state of the compound in real time and adjusting the levels of kinetic and thermal energy inputs in order to achieve a predetermined value of viscosity on discharge. Certain problems exist with the BCC system, including: a) the compound does not form a continuum within the mixer and hence the process is inherently chaotic, with the result that the relationship between torque and viscosity cannot be defined with certainty. b) the method involves the use of rotor torque as a measure of viscosity, viscosity as a measure of rheology, rheology as a measure of processability, and processability as a measure of extrudability; the relationship rotor torque and extrudability is thus long and inherently inaccurate. An object of a preferred embodiment of the invention, is to overcome the above problems. According to one aspect of the present invention there is provided a batch mixer for mixing viscous materials comprising a housing defining a mixing chamber in which one or more mixing rotors are rotatably mounted, characterised by a sensor system including pilot means for performing a predetermined downstream processing operation on a portion of the mixed product in the mixing chamber and sensor means for sensing a processing characteristic of said mixed product relating to the predetermined downstream processing operation said sensor means producing signals representing the processing characteristic of the material being mixed, and a feedback control loop connected to the sensor and to a control for controlling kinetic and thermal energy inputs in dependence upon the processing characteristic sensed. According to another aspect of the present invention there is provided a method of mixing in a batch mixer comprising a rotatable rotor in a mixing chamber including the steps of feeding material to be mixed to the chamber, characterised by monitoring a processing characteristic of the material being mixed in the chamber by means of a sensor system including pilot means for performing a downstream processing operation and sensor means for sensing a processing characteristic of said mixed product as relating to the predetermined downstream processing operation, producing signals in dependence upon the processing characteristic sensed and employing those signals via a feedback control loop to control the rotor speed, mixing chamber temperature, mixing time and pressure to control the processing characteristic of the material being mixed. In a preferred embodiment of the invention, the mixer comprises two rotors disposed for rotation about horizontal parallel axes. Material to be mixed is fed to the mixing chamber from above and discharged from below the rotors. The processability sensing unit extends through the housing to communicate with the mixing chamber. It comprises means for simulating any downstream processing operation for which it is desired to mix material and in this example comprises an extruder. The extruder has a screw and prescrew disposed in an extruder barrel. The barrel has an outer fixed housing and an inner free housing. The inner free housing defines an annular recess in which a sensor is disposed. The screw is connected to a drive via a drive coupling. The sensor is connected to a feedback loop which includes a computer which is programmed to control the rotor speed, mixing chamber temperature, ram pressure, time and other mixing characteristics in dependence upon the sensor signals. In order that the invention may be more clearly understood, one embodiment thereof will now be described, by way of example, with reference to the accompanying drawings, in which:- Figure 1 shows a diagrammatic cross sectional view of a mixer incorporating a sensing system according to the invention, and Figure 2 shows a detailed view of the sensing system shown in Figure 1. Referring to Figure 1, the mixer itself is conventional and comprises a mixer body 1 defining a mixing chamber 2 in which two rotors 3 and 4 are mounted for rotation by means of an electric motor (not shown). Material to be mixed is fed to the chamber through a conventional feed arrangement 5 and oil (if required) is fed to the chamber via the port 6. Mixed material is discharged from the mixer through an outlet 7 at the base of the mixer. The mixed material is usually then processed through a mill or a dump extruder prior to being fed to an extruder and the state of "mixedness" of the material should be acceptable to the requirements of the extruder. It is these requirements which form the theoretical basis for the mixer development of the present invention. Leading into the mixing chamber 2 on that side of the mixer remote from the oil inlet port 6 is a further port 8. Attached to this port 8 is a processability sensing system 9 operative to monitor the flow and deformation characteristics (extrudability) of the material being mixed. This is connected to a feedback control loop 10 which leads to a computerised control 11 operative to control rotor speed and mixing chamber temperature characteristics R and T, and ram pressure and time and other mixing characteristics in dependence upon the signal fed from the processability sensing system 8. Referring additionally to figure 2, the processability sensing system comprises a pilot extruder having an extruder screw and pre-screw 20 and 21 respectively disposed inside an extruder barrel 22 and mounted in a bearing 19. The barrel 22 fits inside the port 8 leading into the mixing chamber 2 so that material from the chamber can enter the pilot extruder. The extruder barrel 22 comprises a fixed housing 23 and a free housing 24. The free housing 24 surrounds the extruder screw towards that end of the screw 20 remote from the mixing chamber 2 but upstream of a die passage 26a and is disposed between the screw 20 and the fixed housing 23. The free housing 24 defines an annular recess 25 in which a torque sensor 26 is disposed. In use, this sensor produces a signal in dependence upon the reaction torque to which the free housing 24 is subjected when driven by drive 27. The sensor also produces signals representing temperature, pressure, die swell and other extrusion characteristics. Drive 27 is connected to drive screw 20 through a drive coupling 28. The sensor is connected to the feedback loop 10 and computerised control 11 already mentioned. This control 11 controls the mixing chamber 2 temperature, the speed of the rotors 3 and 4 through a variable speed control, ram pressure, time of mixing and other mixing characteristics in dependence upon the signal fed to it from the sensor. In effect therefore, the mixing characteristics of the material being mixed are directly controlled by the same type of apparatus (an extruder) for which the mixed material is to be handled thus leading to better and more predictable results. By equating the final level of internal energy and entropy directly with the processability/extrudability of the mixed material and mixing according to the latter criterion, any batch-to-batch variations in the initial intenal energy levels are automatically compensated for and a uniform level of processability is obtained.

Claims: A batch mixer for mixing viscous materials comprising a housing (1) defining a mixing chamber (2) in which one or more mixing rotors (3,4) are rotatably mounted, characterised by a sensor system (20,21, 22,23,24,26,27) including pilot means for performing a predetermined downstream processing operation on a portion of the mixed product in the mixing chamber and sensor means for sensing a processing characteristic of said mixed product relating to the predetermined downstream processing operation said sensor means producing signals representing the processing characteristic of the material being mixed, and a feedback control loop (10) connected to the sensor and to a control (11) for controlling kinetic and thermal energy inputs in dependence upon the processing characteristic sensed. A batch mixer as claimed in claim 1, in which two rotors (3,4) are disposed for rotation about parallel axes. A batch mixer as claimed in claim 1, in which means are provided for feeding material to the mixing chamber (2) from above the mixer. A batch mixer as claimed in claim 1, in which means are provided for discharging material downwardly from the mixer. A batch mixer as claimed in claim 1, in which the sensor (26) extends through the housing (1) to communicate with the mixing chamber (2). A batch mixer as claimed in claim 1, in which the sensor system comprises an extruder (20,21,22). A batch mixer as claimed in claim 6, in which the extruder has a screw (20) disposed in an extruder barrel (22). A batch mixer as claimed in claim 7, in which the barrel has an outer fixed housing (23) and an inner free housing (24). A batch mixer as claimed in claim 8, in which the inner free housing (24) defines an annular recess (25) in which a sensor (26) is disposed. A batch mixer as claimed in claim 6, in which the screw (20) is connected to a drive (27) via a drive coupling (28). A batch mixer as claimed in claim 6 in which the extruder (20,21,22) contains or has attached to it extrusion passages and/or die configurations (26a). A batch mixer as claimed in claim 1, in which the sensor (26) is connected to a feedback loop (10) which includes a computer operative to be programmed to control the rotor speed, mixing chamber temperature, ram pressure, time and other mixing characteristics in dependence upon sensor signals. A method of mixing in a batch mixer comprising a rotatable rotor (3,4) in a mixing chamber (2) including the steps of feeding material to be mixed to the chamber (2), characterised by monitoring a processing characteristic of the material being mixed in the chamber by means of a sensor system (20, 21,22,25,26,27), including pilot means for performing a downstream processing operation and sensor means for sensing a processing characteristic of said mixed product as relating to the predetermined downstream processing operation, producing signals in dependence upon the processing characteristic sensed and employing those signals via a feedback control loop (10) to control the rotor speed, mixing chamber temperature, mixing time and pressure to control the processing characteristic of the material being mixed.

Inventors: BROWN CHRISTOPHER JOHN, BROWN, CHRISTOPHER JOHN
Applicants: SHAW FRANCIS & CO LTD, FRANCIS SHAW & COMPANY (MANCHESTER) LIMITED
Application year: 1990
Main classification: B29B7
IPC codes: B01F7, B29B7, B29K21