United States Patent [191 [11] 4,251,475

Varrasso et al. [45] Feb. 17, 1981

[54] METHOD AND APPARATUS FOR Attorney, Agent, or FirmRonald C. Hudgens; Patrick
CONTROLLING THE PROPORTION OF P. Pacella; Joel I. Rosenblatt
LIQUID AND DRY PARTICULATE MATTER
ADDED TO A PELLETIZER [57] h ABSTRACT f n
_ A met od and apparatus are provided or contro ing
[75] Inventors: Eugene C varrasso Heath; Rlclmd the amount of dry particulate matter and liquid added to
K Henry Newark both of Ohm a rotary pelletizer. A transducer placed within the pel
[73] Assignee; ()wens.(joming pibel-glas letizer senses a characteristic of the mixed material in
Corporation, Toledo, Ohio the pelletizer. This characteristic may be, for example,
the level of the batch or the size of the pellets. The
[21] Appl" No': 9745456 transducer signal is then conditioned to provide a signal
[22] Filed; Dec_ 29, 1978 level corresponding to a desired characteristic level and
which varies about that level corresponding for exam
[51] Int. Cl.3 ....................... .. B01J 2/12; B28B 17/00; ple to the variations of pellet size about a desired size.
B29B 1/03; C09C 1/28 That signal is added to a second signal representing the
[52] US. Cl. .............................. .. 264/401; 23/230 A; actual liquid ?ow into the pelletizer ot- added to a Sec
23/313 R3 23/313 P; 264/117; 364/500; 0nd signal representing actual dry particulate flow into
_ 422/111; 425/140; 425/222; 425/DIG' 101 the pelletizer and modulates that respective flow to
[5 3] Fleld of Search --------- -- 23/313 R 313 AS 313 P maintain the input of either the dry or the liquid mate
23/230 A; 264/491 40-4 40-7 117; 425/140 rial into the pelletizer as necessary. Additionally, a set
141, 145, 222, DIG. 101; 364/108, 496, 500, point signal can be provided as a constant signal repre
5023 422/110 111 senting desired dry particulate in ?ow or liquid in How.
[56] References Cited The dry or the liquid signal also can be derived from the
respective actual liquid or dry signal by taking a proper
U'S PATENT DOCUMENTS proportion of the other signal. Additionally, a method
3,656,911 4/1972 Hobbs .......................... .. 23/23() A X and apparatus is shown for controlling the liquid input
3,733,473 5/1973 Child et al 23/230 A X to the pelletizer in response to the actual dry material
3,383,231 5/ 1975 Holley - - - - - t - - - ~ - - - - t ' -- 425/222 ?ow into the pelletizer so that the correct proportion of
3,951,604 4/1976 Smith .et a1 - 364/500 X liquid to dry particulate is always maintained regardless
4,091,060 5/1978 Carter et al 425/222 X of the actual ?ow~
4,131,668 12/1978 Sasaki et al. .................. .. 264/404 X

Primary Examiner-Joseph Scovronek 12 Claims, 5 Drawing Figures

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US. Patent Feb. 17, 1981 Sheet 1 of4 4,251,475

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US. Patent Feb. 17, 1981 Sheet 2 of4 4,251,475
 4,251,475
1 2
tion of the pellets can result in forecast or prediction of
METHOD AND APPARATUS FOR CONTROLLING pellet size so that the quantity of water or batch to
THE PROPORTION OF LIQUID AND DRY water ratio can be changed to avoid an undesired in
PARTICULATE MATTER ADDED TO A crease or decrease in pellet size prior to its happening.
PELLETIZER For example, the depth of the batch material in the
pelletizer at certain portions thereof can be measured
FIELD OF THE INVENTION and the water ?ow changed accordingly. An increased
This invention relates to control systems for a pellet depth of the nuclei or seed of the batch material indi
izer and particularly pelletizers where liquid and dry cates that water content is higher, the water tending to
particulate matter are combined as in a rotary pelletizer, cause the seeds to stick together more and thus build up
and further where the pellets may be used in a melting higher. Consequently, the amount of water supplied to
furnace such as a glass furnace. the pelletizer is reduced when the sensing device indi
cates that the batch depth has reached a predetermined
BACKGROUND value. The excess water would otherwise tend to make
It has been found to be advantageous to collect the fewer but larger diameter pellets, if not reduced. At the
hot combustion gases produced in a glass melting fur same time, if there is too little water, the depth of the
nace or unit and to pass them in heat-exchange relation nuclei or seeds of the batch decreases with the amount
ship with the batch material being supplied to the melt~ of Water then being increased. The lesser amount of
ing furnace. The batch can thus be preheated to ele water otherwise would result in the individual ?nal
vated temperatures to save signi?cant amounts of en pellets thereby being smaller but in greater quantity.
ergy subsequently required to melt the batch. The ex Among the pertinent prior art is a US. Pat. applica
haust gases otherwise are simply expelled to the atmo tion of Stephen Seng Ser. No. 809,595 ?led June 24,
sphere in many instances with a considerable waste of 1977, which is assigned to the common assignee with
heat and energy. this application. That disclosure substantially describes
Preferably, the heat-softenable batch material is in the 25
the foregoing. Additionally, an application of Richard
form of balls or pellets in the heat-exchange chamber K. Henry, Ser. No. 974,470, which was ?led on Dec. 29,
through which the hot gases are passed. However, it 1978, now abandoned, a continuation-in-part applica
has been discovered that the pellet size must be substan
tially uniform. Otherwise, pellets of varying sizes tend tion, Ser. No. 095,268, having been ?led Nov. 29, 1979,
to nest and provide excessive restriction to the flow of both of which are assigned to the common assignee
the gases past the pellets in the chamber. It has also been disclose directly sensing pellet size as a sensed charac
discovered that pellets size is important in addition to teristic and proportionally controlling the liquid inflow
uniformity. If the pellets are too small, again undue responsively.
restriction to the flow of the hot gases results. If the However, regardless of the type of characteristic
pellets are too large, their surface-to-weight ratio is 35 measured and the type of particulate matter or liquid
accordingly reduced and the heat transferred to them is being used in the pelletizer, both the prior application of
accordingly decreased. Also, trapped moisture in the Seng and the co-pending application of Henry indicate
larger pellets may turn to steam and cause the pellets to that control of the proportion of dry and liquid material
explode. Speci?cally, it has been found that pellets of is necessary in order to control the quality of the pellets
one-half inch nominal diameter with a range from three 40 being produced in the pelletizer.
eights inch to ?ve-eights inch in diameter are the ulti The co-pending application of Richard K. Henry
mate for obtaining maximum heat transfer from the hot further indicates that it is also desirable to control the
exhaust gases to the pellets. amount of liquid to the amount of dry material going
The pellets of the heat-softenable batch material pref into the pelletizer. This means that within practical
erably are made in a modi?ed commercially-available 45 limits, certain pellet compositions require a strict pro
pelletizer. The components of the batch are mixed to portion of liquid to dry particulate matter be maintained
gether and then supplied to the pelletizer. During trans in the pelletizer and that any variation in either the
portion to the pelletizer, the batch components tend to liquid or dry particulate matter be matched by a propor
segregate so that the actual batch supplied to the pellet tional compensating adjustment for the dry or the liquid
izer will vary, even though the ?nal pellets produced matter respectively going to the pelletizer.
and supplied to the melting furnace or unit average out Additional prior art references, are US. Pat. Nos.
so that the short variations are not material. However, 4,031,175 and 3,277,218 which show proportional con
the short variations in the batch components tend to trol of the liquid in flow. However, they do not show a
affect the pellet-forming ability of the batch and the size rotary pelletizer wherein a varying characteristic of the
of the pellets produced, other factors being constant. material is sensed and the transduced signal is condi
The feed rate of the batch to the pelletizer will also vary tioned to match the variations of the characteristic
and thereby also affect pellet forming and pellet size. about a desired level. They further do not show a modu
Liquid, and speci?cally water, is also supplied to the lator circuit as necessary to match the input require
pelletizer with the batch supply. With the batch compo ments of a large control system while producing a signal
nent or quantity variation, different size pellets will matching the variations of the material in the pelletizer.
result when the water quantity is held constant. How
ever, it has been found that the water quantity, or the SUMMARY OF THE INVENTION
ratio of the batch to the water, will also affect the pellet In accordance with the objects associated with the
size, with more water resulting in larger pellets and less wide range of materials used in the pelletizer as well as
water resulting in smaller pellets, at least in most in 65 the control needs of the varying compositions, the fol
stances. lowing method and apparatus is disclosed.
It has also been discovered that measuring a charac This pelletizing control method and apparatus is de~
teristic of the batch in the pelletizer during the forma signed for use with glass batch compositions to form
 4,251,475 4
3
heat softenable pellets but may be used in a greater ence level third signal is then a set point, and compared
variety of pelletizing operations and the principals of with the ?rst and second signals to generate the error
this invention should not be thought of as being limited signal.
to either glass batch pellets or even more generically to For example an actual dry particulate rate signal,
heat softenable pellets but may be applied to any type of provided by a dry particulate ?ow transducer, could be
pellet forming operation. used in place of the dry particulate rate set point arti?
In accordance with the invention, a varying charac cially generated level signal. In this case, the same pro
teristic of the material in the pelletizer is sensed and this portional liquid signal would be derived and used as the
characteristic is controlled in turn to control the charac third signal reference level set point signal so that the
teristics of the pellets being produced. 10 rate of liquid input to the pelletizer is always in the same
A transducer is used to sense this characteristic and required proportion regardless of a change in the actual
then means are provided to generate a conditioned ?rst feed rate for the dry particulate material. In this case the
signal responsive to the sensed varying characteristic to dry particulate input rate need not be controlled as the
ultimately control the quality of pellets. This ?rst signal liquid input rate would be controlled instead to provide
is conditioned to have a predetermined level corre 5 the correct proportion of liquid regardless of any
sponding to a predetermined characteristic level. The change in the dry particulate in flow. In this way the
signal modulates or deviates from the predetermined same quality of pellets and the same predetermined
level responsive to the variations in the said characteris characteristic level within the pelletizer would be pro
tic level about the desired predetermined characteristic duced.
level. 20 In furtherance of the control system for the operation
The ?rst signal then is made responsive to the materi of the pellets and in particular the pelletizer and in
als varying characteristic and more particularly particular the production of the pellets, a unique modu
matches it. It has a level corresponding to the desired lator circuit is shown. This modulator circuit provides
level of the varying characteristic and varies about its two sections each capable of providing a predetermined
level as the characteristic in the pelletizer varies ~about 25 level signal corresponding to the said varying charac
its own respective level. The ?rst signal modulates teristic predetermined level and capable by itself of
about a desired level corresponding to the desired char producing the said ?rst signal to match or duplicate the
acteristic level. movement of the characteristic about its predetermined
Recognizing that in pelletizers, it is desired to main characteristic. In addition the two sections may be com
tain the correct proportion of one ingredient to another bined to provide even greater versatility as may be
ingredient or particularly of liquid to dry particulate necessary in a pelletizer control system to match the
material, either the rate of the dry particulate material output of the pelletizer to an analogue or digital control
into the pelletizer or the rate of liquid into the pelletizer system.
may be sensed to generate the second signal. This sec In this regard, a ?rst section has an integrating ampli
ond signal similar to the ?rst signal also has a level ?er to smooth out variations in the transducer output
corresponding to a desired input rate and deviates about and an adjustment circuit which may be used to provide
that desired input rate responsive to the deviation of one the said predetermined level at the output of the ampli
ingredient input rate, the liquid or dry input rate. ?er corresponding to the predetermined characteristic
The ?rst and second signals may be combined to level in the pelletizer. The output of the integrating
produce a fourth signal having a predetermined level 40 ampli?er could then be the said ?rst signal having a
which corresponds to both the ?rst and second signals predetermined level corresponding to the predeter
being at their respective predetermined levels and to the mined characteristic level and varying about that level
said varying characteristic being at its predetermined responsive to variations of the characteristic about its
characteristic level and with the fourth signal deviating predetermined characteristic level. The output of the
about its respective level corresponding to the deviation 45 integrating ampli?er can be connected directly to a
of the ?rst and second signal deviating about their re control system.
spective levels and responsive to the characteristic A second section of the modulator uses a feedback
within the pelletizer varying about its predetermined ampli?er to produce a signal which is then modi?ed in
characteristic level. level to provide a modi?ed feedback input to the ampli
Further in accordance with this control scheme, the ?er, with that modi?ed level corresponding to the pre
?rst and second signals, or the fourth signal is then determined level of the characteristic. The ampli?ed
compared with a reference level third signal to produce output of a feedback ampli?er may be adjusted in sensi
an error signal. This error signal is then minimized to tivity to control its response, responsive to the input of
bring the modulated ?rst signal to its predetermined the ampli?er. This sensitivity corresponds to the rate of
level, indicating that the characteristic is being main 55 change of the feedback ampli?er output to a change in
tained at its predetermined level. transducer output or input from the integrating ampli
The reference level can be actual measured in?ow for ?er. This second ampli?er may be connected at its input
the other ingredient or may be arti?cially generated to to the transducer to provide a conditioned signal having
indicate desired or assumed level for the other ingredi a level and a sensitivity which may be modi?ed to
ent or may be arti?cally generated to indicate a desired match the needs of a control system connected to the
level for the said one ingredient. feedback ampli?er output and wherein the feedback
For example, the dry particulate rate provided as a ampli?er then produces a signal having the said prede
signal level by a signal generator can be further condi termined level corresponding to the varying character
tioned by a constant K to generate the set point third istic level and varying about that level in response to the
signal for the liquid rate into the pelletizer. This liquid 65 variations of the characteristic.
rate would be a proportion of the dry rate and would As stated, the input of the feedback ampli?er may be
represent the proper liquid input rate for the desired or connected directly to the transducer or may be con
actual dry particulate rate chosen. This derived refer nected to the transducer through the output of the inte
 4,251,475
5 6
grating ampli?er where the integrating ampli?er adjust to monitor and adjust the system and control parame
ment circuit would be used as a one to one ampli?er. ters.
The ?rst and second circuits could be used coopera
tively to provide greater versatility within the'control DESCRIPTION OF THE DRAWINGS
scheme. This greater versatility is provided, for exam 5 FIG. 1 is a schematic view in elevation of apparatus
ple, by using the integrating ampli?er to operate a dis of forming batch material into pellets.
play device which displays the motion of the character FIG. 2 is an enlarged diagrammatic view of the disc
istics as it varies about its predetermined characteristic of the pelletizing apparatus in FIG. 1.
level while serving as an input to the second portion of FIG. 3 refers to a type of transducer which may be
the modulating device. The second portion of the mod used to sense the characteristic of the material in the
ulating device may condition the output of the integrat pelletizer and which may be interchanged with any
ing ampli?er again to provide the said signal level re other suitable transducer for producing the required
sponsive to the predetermined characteristic level and signal indicative of the varying characteristic.
an output varying about the level and further provide FIG. 4 shows in schematic form the control system
the necessary conditioned signal to the input of a larger including the pelletizer.
control system for controlling the inflow of either water FIG. 5 shows in schematic form the modulator
or dry particulate to the pelletizer. In this case, both the within the control system which produces a signal hav
means for adjusting the signal level of the integrating ing a level corresponding to the varying characteristic
ampli?er and the means for modifying the signal level desired level and varying about the characteristic ac
of the feedback ampli?er to obtain a desired predeter 20 cording to the said characteristic variations.
mined ?rst signal level responsive to the level of the
predetermined level of the varying characteristic as DESCRIPTION OF THE PREFERRED
well as the sensitivity of the feedback ampli?er are EMBODIMENT
controlled to maintain the proper amplitude for use in Referring to FIG. 1, particulate, heat-softenable glass
driving the further portions of the control system. 25
batch material is transported to a supply hopper 10 and
Further in accordance with this invention and where
the sensor within the pelletizer is placed in operation subsequently supplied to a pelletizer 12. The particulate
batch material is formed into pellets which are dis
subsequent to the said varying characteristic reaching
its predetermined level, the ?rst portion of the modula charged onto a trough 14 having openings 16 therein
tor circuit may be separately adjusted with respect to through which smaller or broken pellets can be sepa
the transducer to zero the transducer output level with rated. The pellets can be supplied to a suitable vertical
respect to the predetermined characteristic level and to conveyor and carried to the top of a heat-exchange
separately inspect the transducer outut level to insure it hopper forming a heat-exchange chamber. The pellets
is operating properly. At the same time the second then move down to a melting furnace after being pre
portion of the modulating circuit can be separately heated with hot combustion gases therefrom in the
adjusted to provide the critical conditioned signal input chamber. A substantial increase in ef?ciency of the
required for the input to the control system. furnace is thereby achieved.
The characteristic itself may be sensed physically by As previously recognized, size uniformity of the pel
a paddle as shown in this disclosure or any other type of lets is important, since if the size varies too much the
suitable transducer. What is important is that the char 40 pellets tend to nest together and excessively restrict the
acteristic sensed varies in proportion to the amount of ?ow of exhaust gases through the heat-exchange cham
water and dry particulate being added to the pelletizer. ber. The actual diameter is also important because if the
As stated above the principles of this invention are not pellets are too small they produce excessive restriction
restricted by the type of transducer used or whether the to the ?ow of gases, and if the pellets are too large, the
characteristic is measured inside or outside the pellet 45 surface-to-weight ratio is less and less heat is transferred
izer. For example, the characteristic measured could be to them. Further the larger pellets may have moisture
?nished pellet size as shown in copending applicationiof trapped therein and explode when the moisture turns to
E. Varrasso, Ser. No. 974,418, ?led Dec. 29, 1978, and steam. Pellets having a nominal diameter of one-half
assigned to the common assignee. inch, with a range of three-eighths to ?ve-eighths inch,
This invention accomplishes this control by provid have been found to be the ultimate for obtaining the
ing a unique control scheme which may be used to maximum heat transfer from the hot combustion gases
maintain an input flow rate for liquid, for example, to the pellets.
corresponding to an assumed dry particulate input or The pelletizer 12 forms the batch material into the
may maintain the liquid input rate corresponding to an one-half inch nominal diameter pellets when the condi
actual dry particulate rate as that dry particulate rate tions are properly adjusted. The components of the
changes in accordance with changes in the process batch material supplied to the pelletizer 12 from the
means or materials. supply hopper 10 may segregate during transportation.
Further a modulator circuit is provided for condition The segregation is not harmful to the operation of the
ing the transducer output to accurately match the glass furnace since the components of the pellets aver
changing phenomena of the said sensed characteristic 60 age out over a period time. However, the short varia
while affording the opportunity to adjust the signal tions in the batch components affect the pellet-forming
output to match the needs of a larger control system. ability of the batch material. Thus, variations in compo
The modulator also provides the versatility which may nents of the batch material supplied to the pelletizer 12
be used to connect its output to various display devices will result in change in pellet size when other factors
and other control means. A further advantage is pro 65 remain constant. The feed rate of the batch to the pellet
vided by the modulator circuit permitting a human izer may also vary and again change the pellet-forming
operator to initiate the process by placing the trans ability and the pellet size. Segregation and variation in
ducer in operation at his discretion and by allowing him certain batch compositions are more critical than for
 4,251,475
7 8
many others, rendering close control of liquid quantity Accordingly, referring to FIG. 3, the stem 56 of the
very important. paddle 54 is af?xed to a disc 64 on shaft 62 and is af?xed
The quantity of liquid or the ratio of the liquid to the to one end of a wire 66. The shaft 62 is mounted on
batch material affects the pellet size, with an increase in support 67 (FIG. 1) above the pelletizer disc. The wire
the amount of liquid or water or increase in the ratio 66 is connected to a core of a linear transducer 68 with
resulting in larger pellets, and with less water resulting the wire and paddle urged to a downward position by a
in smaller pellets. It has been found that by measuring a compression spring .70. The material or batch in the
characteristic, for example the size or diameter, of the rotary pelletizer then moves the paddle and causes a
partly-formed pellets moving in a downward path on responsive signal to be produced at the output of trans
the pelletizing disc, or the depth of the batch, the water ducer 68.
quantity can be controlled proportionally. Larger pel The combination of a paddle and linear transducer is
lets indicate that there is more water and that the quan shown as one example for a means for sensing the vary
tity should be reduced while smaller pellets indicate less ing characteristic within the pelletizer and any other
water and that the quantity should be increased. suitable sensing means can be used in its place either
Referring to FIGS. 1 and 2 the means for forming inside or outside the pelletizer, for sensing the varying
pellets is shown as and may include the pelletizer 12 and characteristic of the mixture.
movable surface 18 in the form of a rotatable member or FIG. 4 shows the pelletizer and the control system in
disc. The disc 18 is rotatably carried on a bearing hous schematic form.
ing 20 (FIG. 1) which is pivotally mounted on cars 22. This invention is a control system for controlling the
The ears 22 are carried on an axle 24 which is mounted 20 proportion of at least two ingredients mixed in a pellet
on a stand 26. The disc 18 is rotated by a motor 28 izer to form pellets and for controlling the size of the
through drive and driven sprockets 30 and 32 and a pellets. The invention senses a characteristic of the
chain 34. The disc 18 is surrounded by an annular parti mixture within the pelletizer and produces a ?rst signal
tion or wall 36, with the pellets tumbling over the wall responsive to that sensed characteristic. It senses a flow
and down a spout 38 to the trough 14 when they are of 25 rate for one of the said ingredients and produces a sec
?nal size. An outer plow 40 and an inner plow 42 scrape ond signal responsive to that ?ow rate. It produces a
and clean the surface of the disc 18. reference level third signal which is then used as a set
Batch from the supply hopper 10 is fed to a lower signal and compared with the ?rst and second signals to
central portion of the disc 18, as indicated in FIG. 1, by produce an error signal. The error signal is then used to
a suitable feeder 44 (FIG. 1). The feeder is shown as 30 control at least one of the ingredients and to control the
having a belt conveyor 46 driven by a motor 48. How proportion of ingredients mixed in the pelletizer.
ever, other feeders could be employed, such as vibra The reference level third signal is also known as a set
tory ones. While the feeder is intended to supply a con signal. It may be derived in a number of ways without
stant quantity of batch, as a practical matter, the feed departing from the principles of this invention. It may
rate of substantially any feeder is subject to some varia 35 be arti?cially generated or may be responsive to actual
tion. This variation requires changes in the water sup ?ow rate. Where it is arti?cially generated, it may rep
plied to maintain pellets of constant size even though resent a pure reference level. As a pure reference level
the batch components do not vary. In this example, it may be combined either with the ?rst signal for the
water is supplied to a middle right-hand portion (FIG. sensed characteristic or with the second signal for one
2) of the rotatable disc 18 by a supply line 50 (FIG. 1) 40 ingredient or with the combined ?rst and second signals
and a nozzle 52. The water is supplied in a flat spray at to produce a minimum error signal when the system is
roughly a three oclock position. in balance: the ?rst signal indicates the sensed charac
With the disc 18 rotating in a clockwise direction, as teristic is at the proper level and the second signal indi
shown in FIG. 2, the surface of the disc is slanted at a cates the flow rate for one of the said ingredients is at
predetermined angle to the horizontal, such as forty 45 the proper ?ow rate.
degrees. The batch then moves in generally elliptical In the most simple form, the control system may
paths as it is carried in a clockwise direction up the compare the ?rst signal, which is indicative of the
periphery of the disc and moves down the disc at least sensed characteristic level with a reference level to
partially under the influence of gravity. More speci? generate an error signal, which may then be used to
cally, the particulate batch moves in an arcuate upward control the inflow of one ingredient. Alternatively, the
path around the periphery of the disc 18, adjacent the ?rst signal may be directly coupled to a controller,
partition or wall 36. The batch and partly-formed pel which then would generate a control signal, responsive
lets then move downwardly along three rather distinct to the said ?rst signal, for controlling one of the ingredi
paths. In the outer path, designated as such in FIG. 2, ents.
there are seeds or nuclei of the batch on which the When the ?rst and second signals are combined with
pellets form. In the intermediate or middle path, there each other to produce a fourth signal the fourth signal
are partially-formed pellets generally having diameters may be combined with the reference level third signal
in the order of one-fourth inch. In the inner path, there to produce a minimum error signal when the system is
are ?nished pellets which move in a continuous tight in balance.
elliptical path until they tumble over the annular parti In use, the reference level third signal may be more
tion 36. The three downwardly moving paths are than a pure reference level and may be indicative of an
known in the art as holdup or load. actual system parameter or a desired level for a system
The means for sensing the characteristic of the mate parameter: it may be the actual flow rate for one of the
rial may be any suitable transducer. As shown in the ingredients or it may be an arti?cially generated signal
preferred embodiment a paddle 54 is positioned in the 65 indicative of a desired ?ow rate for one of the ingredi
pelletizer relative to one of the three streams dependingents. Where the reference level third signal is indicative
on batch composition. Typically, each separate compo of other than the one ingredient represented by the
sition would have a preferred paddle location. second signal it is converted to a corresponding value
 4,251,475
10
or level for the one ingredient before it is used as a set responsive to the physical displacement of that paddle
signal and compared with the second signal represent by the material in the pelletizer. However, this inven
ing the one ingredient. For example, where the other tion should not be thought of as limited to the particular
ingredient is dry particulate and the one ingredient is embodiment for the transducer shown within the pellet
the liquid, the second signal is then indicative of liquid, izer as other suitable means may be used to sense the
and the reference level third signal must be converted characteristics of the material in the pelletizer and the
by a constant to a new level corresponding to that pro principles of this invention should be recognized as
portion of liquid ?ow required to produce the correct applying to a control system for identifying, measuring
size pellets when combined with the dry particulate and controlling a characteristic of the liquid-dry mix
flow represented by the reference level third signal. - 0 ture as it changes about a desired level within the pellet
Then when the second signal corresponding to liquid izer to produce the desired quality pellets at the output
?ow rate for example is compared to the reference level 113. 4
third signal (set signal), the comparison is between the Further this invention should not be thought of as
actual ?ow rate for the liquid as indicated by the second limited to a particular type of pelletizer as the invention
signal and the reference level or set level for that liquid 5 is to the method and apparatus for controlling a charac
?ow rate. Where the arti?cially generated reference teristic of the liquid-dry mixture as it varies through the
level third signal is indicative of the one ingredient then formative pellet stages.
no conversion is necessary as the comparison is between The output signal from the sensing means 131 indicat
the third reference level set signal indicative of a desired ing the level of the varying characteristic within the
level for the one ingredient and the second signal indic 20 pelletizer is provided to a modulator 133, which is also
ative of the actual ?ow level for the one ingredient. disclosed in copending application Ser. No. 974,419,
The principles of this invention may be practiced which was ?led Dec. 29, 1978, and is assigned to the
using any suitable combination of actual or arti?cially common assignee, is further explained in detail with
generated signals for the one or the other of the ingredi reference to FIG. 5. The output of that modulator is a
ents. For example, the reference level may be an arti? 25 signal which has a predetermined level, corresponding
cially generated level for a desired liquid flow rate to the desired characteristic level. This level in turn for
representing the ?rst ingredient, where the second sig example where a paddle was used would correspond to
nal represents actual liquid flow rate. Or the reference a desired paddle position or paddle level.
level third signal may represent the actual or desired The modulator 133 signal level would then corre
flow rate for dry particulate where the second signal spond to a predetermined displacement of the paddle
represents the actual of flow rate for the liquid. In this producing a predetermined signal output at the paddle
case the third reference level signal must be converted transducer 131. For example, as the case of a paddle, the
to a new level representing that proportion of liquid paddle would be displaced about a desired level corre
flow rate corresponding to the actual or desired dry sponding to desired pellet size or a desired batch level
flow rate required to form the proper size pellets. and produce a varying signal input to the modulator
The overall control system refer to generally by nu 133. Modulator 133 would thenproduce a modulated
meral 100. As shown, it employs a feeder or batch bin signal output having a level corresponding to a desired
101 which delivers batch as shown by the arrow displacement of the paddle and varying about that level
through a gravitametric feeder 103. The output of the responsive to the movement of the paddle about its
gravitametric feeder is delivered to a pelletizer 107 desired displacement level.
through a feed slot 105. The gravitametric feeder addi In accordance with the principles of the invention the
tionally has a means 109 for providing an output signal output of, means 127, which is a signal indicating actual
responsive to the rate of ?ow of the dry particulate into liquid ?ow and the output of modulator 133 are input
the pelletizer and a means shown as 111 for controlling ted to combining means 135. In the preferred embodi
the rate of the dry particulate input to the pelletizer, 45 ment, means 135 is a summing means. A combined sig
which may be made responsive to a control system nal is then provided at input 137 of the means for con
output. The output of the pelletizer shown by arrow 113 trolling 139. The signal M at input 137, represents the
is provided to a means 115 which may be used for fur signal output of modulator 133, combined with the
ther pellet processing. The pelletizer output is then actual liquid flow rate signal provided by means 127,
delivered to its end use device as shown in schematic the M standing for measured or actual value. Also,
form by arrow 119. The liquid input to the pelletizer is provided to the controller 139 is a reference level signal
shown by arrow 121 through delivery means 123. shown as a set point signal at input 141 and designated
Within the delivery means 123 is a liquid control valve as S.
125 and a means 127 for generating a signal responsive The output of the means for controlling 139 is an
to the flow of liquid through delivery means 123. The 55 error signal shown at output port 143 and as signal e
means for controlling the liquid flow 125 is responsive which is then provided through distributing means 145
to the output of the control system while the means 127 to either the means for controlling the liquid flow 125 or
provides a signal responsive to that ?ow as an input to means for controlling the dry particulate ?ow 111.
the control system as will be further explained. The algorithm used by controller 139 may use a pro
A signal generator 151 is provided to arti?cially gen portional and integral algorithm to generate error signal
erate a reference level signal for a desired liquid or dry e and expressed as
particulate flow or may be used to generate a pure
reference level signal.
Within the control system, there is shown a further
means 129 for sensing a characteristic of the mixture 65 where S is the reference level shown as a set point signal
within the pelletizer. In this embodiment, it is a paddle at port 141 or converted by means 147 to S as explained
substantially as shown in FIG. 3, placed in the pelletizer below and M is the measured signal. However, other
and producing an output signal through transducer 131 known control algorithms may be used to generate the
 4,251,475
11 12
error signal, such as either strict proportional, or inte wherein the measured signal M to input 137 corre
gral, or derivative or any combination of these func sponds to the actual measured dry particulate and the
tions, consistent with the principles of the invention. A said signal S at input port 141 corresponds to the actual
step or discontinuous algorithm may also be used. liquid in?ow rate which is then converted by convert
The principles of the invention are now described 5 ing means 147 to S corresponding to the proportion of
with reference to the example where one ingredient dry particulate corresponding to the rate of liquid in
represented by the second signal is liquid and the other ?ow and required to produce the desired characteristic
ingredient is dry particulate. in the pelletizer.
It being recognized that for the desired quality of It further being recognized that the error signal can
pellets at the output 113, the correct proportion of liq 10 then be used to control either alternately the ?ow of
uid to dry particulate is required. In this regard, the liquid into the pelletizer or the ?ow of dry particulate
control means 139 includes means for converting 147 into the pelletizer depending upon whether the measure
which converts the value of the reference level shown signal at the input port 137 is responsive to in?ow of dry
as a set point signal S provided at input port 141 by a particulate or liquid respectively.
constant K to produce a new signal S to the means In this control scheme, a transducer 109 connected to
for controlling 139. S represents the correct proportion the means for feeding 103 provides a signal indicative of
of liquid required for either the desired input rate signal the actual ?ow of dry particulate to a switch means 149.
S of dry particulate corresponding to the signal from Additionally connected to switch means 149 is a genera
means 151 or for the actual dry particulate input rate tor 151 which can provide a reference signal level. This
from feeder 103. 20 reference signal level can serve as either a pure refer
S then may be thought as being related to S by a ence signal or an arti?cial desired dry particulate ?ow
constant K which is expressed as a percentage, and may rate or an arti?cial desired liquid ?ow rate. The switch
be expressed by the relationship S'=KS where S repre ing means 149 provides either the signal output from
sents either the desired dry particulate input rate or antransducer 109 or signal generator 151 to input port 141.
actual dry measured input rate, and S represents the 25 Switching means 149 provides the proper connection to
desired liquid input rate proportional to the dry particu either the signal generator 151 or transducer 109 or
late input rate S and where K is nominally greater than transducer 127 depending upon which signal is desired.
1% and less than 99%. As previously discussed, the converting means 147
The error signal e produced at output port 143 is then converts the said signal S to a new said signal S as
provided through the switch means 145 for distribution necessary.
to the means for controlling liquid input 125 and would As an alternative, the measured signal M can also be
then alter the liquid input rate to minimize the error made responsive to the actual dry particulate ?ow rate
signal e indicating that the desired proportion of liquid with the said point signal S, corresponding to the actual
to dry particulate in ?ow has been attained and the liquid ?ow rate. In this case 5 would be that proportion
characteristic within the pelletizer is once again at its 35 of the dry particulate rate corresponding to the mea
desired level. A minimum signal level for error signal e sured in?ow rate of the liquid to give the correct pro
would be consistent with the output of modulator 133 portion of liquid and dry particulate in the pelletizer. S
being at its predetermined level. would be the new said signal for the dry particulate and
The control system is directed to controlling the would be compared with the measured signal M. The
proportion of mixing of two separate ingredients in the 40 measured signal would then comprise the actual dry
pelletizer. It accomplishes this control by comparing particulate in?ow combined with the modulated signal
the actual ?ow of a ?rst of the ingredients with the output from modulator 133.
actual or desired flow of the other of the ingredients so The transducer 109 would then provide a signal to
that the correct proportion of the two ingredients may means 135 indicative of the actual dry particulate in?ow
be maintained in the pelletizer. 45 rate. Modulator 133 output would be combined with
As previously discussed the control is further re?ned the actual dry particulate in?ow rate by means 135 and
by the generation of a ?rst signal corresponding to the provided as the measured signal M to input port 137 of
modulator 133 output signal which is then combined the means for controlling 139. A signal responsive to
with a second signal corresponding to the actual mea the actual liquid in?ow rate provided by means 127
sured inflow of the said ?rst ingredient. 50 through switching means 149 or a generated signal for a
The means for controlling as shown in FIG. 4 then desired liquid in?ow rate would be provided by genera
compares the measured signal M being the combined tor 151 through switch means 149 to input port 141 of
?rst and second signals with a third signal correspond means for controlling 139. In this case, the converting
ing to set point signal. As stated above for this example means 147 converts the said set point signal S to S
the set point signal is derived from the in?ow of the 55 corresponding to that proportion of dry particulate
other ingredient and is converted to a new signal S by required for the measured in?ow rate of liquid into the
means for converting 147 to correspond to that propor pelletizer to give the correct proportion of liquid to dry
tion of the ?rst ingredient for the measured in?ow of material in the pelletizer. It being recognized that in this
the other ingredient, so that the correct proportion of case where a signal generator 151 is to provide the
first and second ingredients is maintained. 60 signal indicative of the desired dry particulate ?ow rate
For illustration purposes, a method and means of then signal S could be made to equal signal S and
mixing a dry particulate and a liquid is discussed with would be compared with the measured signal M at input
reference to the control scheme and where the one port 137 to produce the error signal and no conversion
ingredient is identi?ed as a liquid and the other ingredi by means 147 would be necessary.
ent is identi?ed as the dry particulate. However, it 65 In summary then the control scheme is seen as pro
should be recognized that the control system can easily viding a means for sensing a characteristic in the pellet
be carried out wherein the one ingredient is the dry izer. This means is shown for example by a paddle con
particulate and the other ingredient is the liquid and nected to a transducer 131 which senses movement of
 4,251,475
13 14
the dry and liquid mixture in the pelletizer. A means, The second stage 217 is a feedback ampli?er stage.
being modulator 133, then responsive to that sensed The feedback loop comprises of terminal 226, the resis
signal provides a ?rst signal modulating about a desired tance 227, resistance 229, and resistance 231.
level corresponding to the desired characteristic level. A means for modiying the feedback signal level is
This modulated signal is provided to a means 135 where shown as ampli?er 225, and resistance 223, connected
it is combined with a second signal which may be the between opposite polarities of a power supply. The
actual ?ow rate for the liquid or which may be the output of ampli?er 225 is a feedback signal level modi
actual ?ow rate for the dry particulate. This combined ?ed in response to the setting of resistance 223 which is
signal is then shown as the measured signal M which connected to the input of amplifier 225 through resis
may be identi?ed as a fourth signal and which is com tance 234. Resistance 233 provides a means for chang
bined in the means for controlling with a set point third ing the sensitivity of ampli?er 219.
signal indicative of a pure reference signal or of the As stated above, second stage 217 may be used sepa
other ingredients. Where the ?rst ingredient would be rately in accordance with the principals of this inven
liquid the other ingredient would be dry particulate and tion. In the case where the second stage is used sepa~
vice versa. The means for controlling, including the rately, the ?rst stage is used as a straight through device
means for converting, converts the signal responsive to with the signal at terminal 215 being substantially the
the other ingredient to the proportionate inflow rate for signal of the output of transducer 131 and ampli?er 203
the ?rst ingredient, as explained above, and compares being a one to one ampli?er with or without the inte
the measured signal M with the set point signal S. grating capability as may be desired. In this case, the
As discussed above where the measured signal is the display device may include an ampli?er for amplifying
liquid in?ow rate the said signal S would be the dry the transducer output so as not to load the transducer.
particulate inflow rate which would be converted to The ampli?er 219 will provide an output signal at the
signal S responsive to proportionate amount of liquid output port having an amplitude responsive to changes
required for that measured value of dry particulate 25 in the sensed signal from transducer 133.
?ow. As an alternative, the second stage 217 can be used as
Where the measured signal was of the actual dry a straight throughput device. In this case, the output of
particulate flow rate, the set point signal S would corre transducer 133 is provided to the input of ampli?er 203,
spond to the liquid ?ow rate and then the converted resistance 213 is then adjusted to control the sensitivity
signal S would be that proportionate of dry particulate of the signal at output terminal 215 in response to
corresponding to the set point rate for liquid. changes in transducer input level. The means for adjust
Additionally discussed above was the use of means ing 211 would provide a signal level into ampli?er 203
151 for generating a set point signal S corresponding to which is then combined with the transducer signal level
a desired ?ow rate for either of the ingredients. In ac to provide a proper output signal level at terminal 215
cordance with the preceding the set signals may be corresponding to the, output level of the predetermined
converted or not or used as a pure reference signal. characteristic level. In this case, the output 215, can be
Referring to FIG. 5, the modulator means 133 is now applied to a display device or any other device where
discussed in detail. The modulator is disclosed and the output was to be recorded or displayed.
claimed separately in co-pending application Ser. No. The modifying means, 223 of stage 217 would be
974,419, which was ?led on Dec. 29, 1978, and is as 40
adjusted so that the feed back signal through resistor
signed to the common assignee. 231 to the input of ampli?er 219 would not affect the
As shown in FIG. 5, the modulator contains two
signal into the ampli?er 219 from terminal 215 and am
pli?er 219 would be used as a straight one to one ampli
stages, 209 and 217 connected by terminal 215.
?er.
Each stage may be used to provide the ?rst signal, In actual practice, the two stages 201 and 217 can be
responsive to the variations of the characteristic used cooperatively to achieve a maximum effect. In this
whether liquid or dry particulate and with the other case, the operator would place the transducer in opera
stage being used in a straight through mode. As dis tion when the pelletizer had reached the point where
cussed further, the two stages may be used coopera the characteristic was at its desired level. The operator
tively to produce the modulator output signal. would adjust means 209-so the signal at the output 215
As shown, a transducer 131 has an output connected of the ?rst stage was at the desired level as necessary for
to the input of the first stage represented by variable a display device or any other instrumentation designed
resistor 213 which may be used to alter the sensitivity of to be responsive directly to the variations of the charac
the integrating ampli?er 203 to the input signal. Inte teristic. The operator would then cooperatively adjust
grating ampli?er 203 has connected in a feed back loop the means for modifying 223 and the sensitivity control
resistance 207 and capacitors 205 to provide the proper 233 until the output signal was within the proper limits
time constant as necessary to smooth the fluctations of and at the proper level for use with the control instru
the transducer. mentation as shown in FIG. 3.
An adjustment circuit 209 is shown as a resistance 211 For example, the control means 139 may require a
connected between opposite polarities of a power sup 60 signal of 5 to 25 milliamps and it may be desired to set
ply and provides a second input to the integrated ampli the signal level, corresponding to desired characteristic
?er 203. The output of the integrated ampli?er 203 is level anywhere from 10 to 14 milliamps.
provided to terminal 215 which is connected to the With this arrangement, the operator can manually
input of the second stage 217 and provides an intermedi control the dry or liquid input ?ow and observe the
ate signal to the second stage, or may be connected to 65 effect on the characteristic within the pelletizer as dis
the input of the display device, through resistance Rd, played through the output of transducer 131, and the
or to any other device wherein the output of the termi display device. He can place this transducer in opera
nal 215 may be displayed. tion at the precise moment when the characteristic
 4,251,475
15
within the pelletizer has reached the desired character
istic level.
The second stage 217 of the modulator of FIG. 5 can
then be used to provide a desired signal output matched
to the needs of the larger control system shown in FIG.
4. '
It should be recognized, however, that the value of
the modulator 133 is in its provision of a modulated
signal which follows the movements of the measured
characteristic within the pelletizer and about its desired .
level and which can be adjusted for a level correspond
ing to the desired characteristic level.
We claim:
1. A method of controlling the size of pellets pro
duced by a pelletizer in which ?rst and second ingredi
ents are supplied thereto, said method comprising the
steps of: _ produced by a pelletizer in which ?rst and second in
(a) sensing a characteristic indicative of the size of the
pellets being produced by said pelletizer and gener
ating a first signal responsive thereto;
(b) sensing the rate of supply of said ?rst ingredient to
said pelletizer and generating a second signal re
sponsive thereto; _
(c) combining said ?rst and second signals to form a
third signal;
(d) comparing said third signal with a set point signal
to generate a fourth signal; and
(e) using said fourth signal to modify the ratio of the
rate of supply of said ?rst ingredient to the rate of
supply of said second ingredient.
2. A method as recited in claim 1, further comprising
the step of integrating said ?rst signal, said integrating
step being performed before said combining step.
3. A method as recited in claim 2, wherein said char
acteristic sensing step comprises sensing the depth of
material at a predetermined position on said pelletizer.
4. A method as recited in claim 3, wherein one of said
ingredients is liquid and the other is particulate batch
material and said using step comprises increasing the
ratio of the rate of supply of liquid to the rate of supply
of particulate batch material when the depth of said
material sensed in said characteristic sensing step de
creases and decreasing said ratio when the depth of said
material sensed in said characteristic sensing step in
creases.
5. A method as recited in claim 1, wherein said
method further comprises sensing the rate of supply of
said second ingredient to said pelletizer and generating
a signal responsive thereto for use as said set point sig
nal.
16
v6. A method as recited in claim 1, wherein said ?rst
ingredient is liquid.
7. A method as recited in claim 1, wherein said ?rst
ingredient is particulate batch material.
8. A method as recited in claim 1, wherein said com
paring step comprises generating a fourth signal accord
ing to the equation
where
e: said fourth signal;
Kp: constant;
S: said set point signal;
M: said third signal; and
Ki: constant.
9. An apparatus for controlling the size of pellets
gredients are supplied thereto, said apparatus compris
mg:
(a) means for sensing a characteristic indicative of the
size of pellets being produced by said pelletizer and
generating a ?rst signal responsive thereto;
(b) means for sensing the rate of supply of said ?rst
ingredient and generating a second signal respon
sive thereto; '
(0) means for generating a set point signal;
(d) means for combining said ?rst signal with said
second signal to form a third signal;
(e) means for comparing said third signal with said set
point signal to generate a fourth signal responsive
thereto; and means responsive to said fourth signal
for modifying the rate of supply of at least one of
said ingredients.
10. An apparatus as recited in claim 9, wherein said
comparing means generates a fourth signal according to
the equation
40
where
c: said fourth signal;
Kp: constant;
S: said set point signal;
M: said third signal; and
Ki: constant.
11. An apparatus as recited in claim 9, wherein said
set point signal is indicative of the rate of supply of said
second ingredient.
12. An apparatus as recited in claim 9, wherein said
sensing means comprises means for sensing the depth of
material at a predetermined position in said pelletizer.
* i i t 1k

55

65
 UNITED STATES PATENT AND TRADEMARK OFFICE
CERTIFICATE OF CORRECTION
PATENT N0. : 4,251 ,475
DATED : February 17, 198i
|NVENTOR(S) ; Eugene C. Varrasso and Richard K. Henry
It is certified that error appears in the above-identified patent and that said Letters Patent
is hereby corrected as shown below:

Coiumn i3, Tine 56: The wordv"capacitors" tshouid be changed to

' "Capacitators"

Coiumn T4, Tine 4: ' The word "modiying" should be changed to

. "modifying"

Coiumn i6, Tine 39: The equation should be changed to

e= Kp(S->M)+K1'J(SM)dt
Signed and Sealed this
Twenryithird Day of June 1981
[sun
Arrest:

RENE D. TEGTMEYER

Ana-ring 60?; Acting Commissioner of Patents and Trademarks