Claims:We claim:
1. A high shear mixture granulator having an improved direct drive with permanent magnet synchronous motor comprises:
a granulation assembly, wherein the granulation assembly processes a raw material and prepare granules;
a power transmission assembly, wherein the power transmission assembly transmits and regulates a transmitted power to the granulation assembly during granule preparation, wherein the power transmission assembly comprises a permanent magnet synchronous motor (PMSM);
an end-point monitoring assembly, wherein the end-point monitoring assembly is connected to the granulated assembly and synchronizes a power transmission from the power transmission assembly;
wherein, the power transmission assembly maintains a constant torque supply to the granulation assembly during a speed variation.
2. The granulator as claimed in claim 1, wherein the granulation assembly comprises:
a railing, wherein the railing houses a vertical pendent pipe and a ladder; and
a granulation chamber, wherein the granulation chamber is housed over a base platform placed adjacent to the railing, wherein the ladder is connected to the base platform for easing an accessibility to the granulation chamber;
a hopper assembly, wherein the hopper assembly is connected to the granulator chamber;
a chopper assembly, wherein the chopper assembly is connected to the granulator chamber;
wherein, a raw pharmaceutical particle is inserted to the granulator chamber through the vertical pendent pipe, wherein a predetermined amount of a binder material is added to the raw pharmaceutical particle in the granulation chamber, wherein the granulation chamber produces a required size of granules and discharges to the hopper assembly, wherein the chopper assembly reduces a granule size to a required size during a granulation process in the granulation chamber.
3. The granulator as claimed in claim 2, wherein the granulation chamber comprises:
a bowl, wherein the bowl is clamped to a retractable lid with a mechanical clamper, wherein a pharmaceutical powder is charged in the bowl;
a plurality of vents, wherein the plurality of vents comprising an air vent, a binder vent and a material charging vent are placed on the lid.
4. The granulator as claimed in claim 1, wherein the vertical pendent pipe is attached to a control panel further comprising a human interface, a plurality of switch to control a power transmission to the granulator assembly and the end-point monitoring assembly, and a gauge for measuring a plurality of granulation parameters comprising a granule size.
5. The granulator as claimed in claim 1, wherein the power transmission assembly further with a bowl assembly comprises:
a cylinder assembly, wherein the cylinder assembly comprises a piston housed in a cylinder, wherein the cylinder assembly is connected between the granulator chamber and the hopper assembly;
an impeller assembly, wherein the impeller assembly is connected to the to a bottom surface of the granulator chamber through a cone and a plurality of manual fastening arrangements, wherein the impeller assembly comprises an impeller blade.
6. The granulator as claimed in claim 1, wherein the permanent magnet synchronous motor (PMSM) is fixed to the bowl with an adaptor, wherein the PMSM is further fitted with a cooling mechanism.
7. The granulator as claimed in claim 1, wherein the PMSM and the impeller blade and a hub of the impeller bade are interconnected with a connecting rod and a resting sleeve to controls a gap between the impeller blade and a bottom surface of the bowl.
8. The granulator as claimed in claim 1, wherein the PMSM provides a power transmission directly to the impeller blade, wherein a feedback of transmitted power is withdrawn to monitor an end point.
9. The granulator as claimed in claim 1 increases a power efficiency for granulation process by 13-16%.

, Description:1
FORM 2
The Patents Act 1970
(39 of 1970)
&
The Patent Rules 2003
COMPLETE SPECIFICATION
(See Section 10 and rule 13)
TITLE OF THE INVENTION:
IMPROVED DIRECT DRIVE WITH PERMANENT MAGNET SYNCHRONOUS MOTOR FOR HIGH SHEAR MIXTURE GRANULATOR
APPLICANT:
Tapasya Engineering Works Private Limited
A/212, Road no 30, Wagle Industrial Estate,
Thane (W) – 400 604,
Mumbai , India
PREAMBLE OF THE DESCRIPTION:
THE FOLLOWING SPECIFICATION PARTICULARLY DESCRIBES THE INVENTION
2
A) TECHNICAL FIELD OF INVENTION
[001] The present invention generally relates to a pharmaceutical equipment and particularly relates to an improved direct drive with permanent magnet synchronous motor for high shear mixture granulator. The present invention more particularly relates to a direct drive for high shear mixture granulator with constant torque for the entire range of speed regulation for impeller blade rotation.
B) BACKGROUND OF THE INVENTION
[002] Granulation is an act or process of crystallizing a raw pharmaceutical powder into grains. Granules typically have a size range between 0.2 and 4.0 mm depending on their subsequent use. The granulation process, broadly is a type of particle size enlargement process, and is widely used in the production of solid dosage formulations in the pharmaceutical industry. With various pharmaceutical materials to be used, the granulation is one of the unit and intermediate process to enhance flow, compaction and other properties for the downstream processes and of the final product performance. Since the properties of granules from initial unit operations, have a critical effect on the resultant final granules, the granulation equipment is considered to be the most important equipment in the pharmaceutical manufacturing lines.
[003] One of the widely used granulation process is high shear wet granulation process. A consistency of a wet mass is a function of a distribution of a granulating liquid in available pores and voids present between the powder particles.
3
[004] In high shear granulation equipment, the powder particles are swept through a bowl volume due to force imposed by a fast rotating impeller blades. Then, a liquid typically called as binder is added and distributed over the powder particles. The powder particles stick together to form nuclei, which is consolidated by the impact forces with the impeller and the wall. A granule growth stops when an equilibrium between growth and breakage (caused by impacts of particles, impeller, or wall) is reached. An end point is assumed to be reached when the particle size reaches to its required mean size or distribution.
[005] An end point is measured either by a direct or an indirect method. In indirect method, the end point measurements are predominantly done through:
a) A power consumption by a motor;
b) A direct impeller torque, which essentially require a coupling strain gauge between motor shaft;
c) A torque rheometer which provides an off-line measurement of torque required to rotate the impeller blades
d) A reaction torque, as the impeller shaft rotates. The tension in a stationary motor base is primarily measured by a reaction torque transducer fitted to the frames.
[006] Typically, all the high shear granulation equipment need very high torque requirements with a varying speed regulation requirement. In the wet mixing process, changes in torque occur as a result of a change in the cohesive force of the granules in the wet powder bed
4
[007] The granulation process is monitored by torque or power consumption measurement and a torque depends on a resistance of a mass against rotation of the impeller.
[008] Further in a typical high shear granulating equipment, the power transmission assembly consists a mechanical gear box with different configurations and an AC induction motor. The configurations comprise a spur gear arrangement or a worm gear arrangement. In turn, a main impeller blade is attached to a gearbox shaft. The power and torque values depend on the size of the granulation equipment and the end product characteristics. However, the overall power transmission efficiency is poor and hence the high shear granulating equipment are less energy efficient. Further, a precise measurement of torque and hence the end point determination and a scaling up and a scale down data of the granulation process are difficult with the traditional methods. Further, the gearbox arrangement with coupling, a belt pulley arrangement is noisy and need additional oil lubrication and prone to vibrations and need regular attention and maintenance. Also, the prior art drives are less energy efficient and a higher frame size is always selected resulting in higher footprint and larger space.
[009] Further, due to low mechanical drive efficiency the motor power consumption is different than the impeller power consumption, Also, in AC induction motors, the current lags behind the voltage, leading to inaccurate power calculations.
[0010] Since, the torque characteristics of an AC induction motor across its speed is not consistent and the scale–up of high shear granulation machines with
5
traditional drive system is difficult and not accurate. Hence, there is a need for a high shear granulator with a direct drive and constant torque supply assisting in accurate measurement of the granule size and the end point. Also, there is a need for a high shear granulator with improved power transmission mechanism and power saving characteristics.
[0011] The above mentioned shortcomings, disadvantages and problems are addressed herein, as detailed below.
C) OBJECTS OF THE INVENTION
[0012] The primary object of the present invention is to provide a high shear granulator with a direct drive and constant torque supply assisting in accurate measurement of the granule size and the end point.
[0013] Another object of the present invention is to provide a high shear granulator with improved power transmission mechanism and power saving characteristics.
[0014] Yet another object of the present invention is to provide a direct torque feedback in the high shear mixture granulator without any intermediate mechanical transmission elements to eliminate loss factors.
[0015] Yet another object of the present invention is to provide a highly energy efficient drive for the high shear mixture granulator and reduce a physical size of a power transmission assembly.
[0016] Yet another object of the present invention is to provide a constant torque for an entire range of speed regulation for an impeller blade rotation.
6
[0017] These and other objects and advantages of the embodiments herein will become readily apparent from the following detailed description taken in conjunction with the accompanying drawings.
D) SUMMARY OF THE INVENTION
[0018] The various embodiments of the present invention provide a high shear mixture granulator having an improved direct drive with permanent magnet synchronous motor. The granulator comprises a granulation assembly, a power transmission assembly and an end-point monitoring assembly. The granulation assembly processes a raw material and prepare granules. The power transmission assembly transmits and regulates a transmitted power to the granulation assembly during granule preparation. The power transmission assembly comprises a permanent magnet synchronous motor (PMSM). The end-point monitoring assembly is connected to the granulated assembly and synchronizes a power transmission from the power transmission assembly. The power transmission assembly maintains a constant torque as required by the granulation assembly during and across a speed variation.
[0019] According to one embodiment of the present invention, the granulation assembly comprises a railing, a granulation chamber, a hopper assembly and a chopper assembly. The railing houses a vertical pendent pipe and a ladder. The granulation chamber is housed over a base platform placed adjacent to the railing. The ladder is connected to the base platform for easing an accessibility to the granulation chamber. The hopper assembly is connected to the granulator
7
chamber. The chopper assembly is connected to the granulator chamber. A raw pharmaceutical particulate powder is inserted to the granulator chamber through the opening the lid of the granulator chamber or by other suitable means.. A predetermined amount of a binder material is added to the raw pharmaceutical powder in the granulation chamber. The granulation chamber produces a required size of granules and discharges to the hopper assembly. The chopper assembly reduces a granule size to a required size during a granulation process in the granulation chamber.
[0020] According to one embodiment of the present invention, the granulation chamber comprises a bowl and a plurality of vents. The bowl is clamped to a retractable lid with a mechanical clamper. A pharmaceutical powder is charged in the bowl. The plurality of vents comprising an air vent, a binder vent and a material charging vent are placed on the lid.
[0021] According to one embodiment of the present invention, the vertical pendent pipe is attached to a control panel further comprising a human interface, a plurality of switch to control a power transmission to the granulator assembly and the end-point monitoring assembly, and a gauge for measuring a plurality of granulation parameters comprising a granule size.
[0022] According to one embodiment of the present invention, the bowl assembly and power transmission assembly comprises a cylinder assembly and an impeller assembly. The cylinder assembly comprises a piston housed in a cylinder. The cylinder assembly is connected between the granulator chamber and the hopper assembly. The impeller assembly is connected to the to a bottom surface of the
8
granulator chamber through a cone and a plurality of manual fastening arrangements. The impeller assembly comprises an impeller blade.
[0023] According to one embodiment of the present invention, the permanent magnet synchronous motor (PMSM) is fixed to the bowl with an adaptor. The PMSM is further fitted with a cooling system.
[0024] According to one embodiment of the present invention, the PMSM and the impeller blade and a hub of the impeller bade are interconnected with a connecting rod and a resting sleeve to controls a gap between the impeller blade and a bottom surface of the bowl.
[0025] According to one embodiment of the present invention, the PMSM provides a power transmission directly to the impeller blade. A feedback of transmitted power is withdrawn to monitor an end point.
[0026] According to one embodiment of the present invention, the granulator increases a power efficiency for granulation process by 13-16%.
[0027] These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.
9
E) BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The other objects, features and advantages will occur to those skilled in the art from the following description of the preferred embodiment and the accompanying drawings in which:
[0029] FIG. 1 illustrates a side view of a high shear mixture granulator, according to one embodiment of the present invention.
[0030] FIG. 2 illustrates a top view of the high shear mixture granulator, according to one embodiment of the present invention.
[0031] FIG. 3 illustrates an external arrangement of a granulator assembly in the high shear mixture granulator, according to one embodiment of the present invention.
[0032] FIG. 4 illustrates a sectional view of the granulator assembly in the high shear mixture granulator, according to one embodiment of the present invention.
[0033] FIG. 5 illustrates a graphical representation of a torque and a power variations during a granulation process in the high shear mixture granulator, according to one embodiment of the present invention.
F) DETAILED DESCRIPTION OF THE DRAWINGS
[0034] In the following detailed description, a reference is made to the accompanying drawings that form a part hereof, and in which the specific embodiments that may be practiced is shown by way of illustration. The embodiments are described in sufficient detail to enable those skilled in the art to practice the embodiments and it is to be understood that the logical, mechanical
10
and other changes may be made without departing from the scope of the embodiments. The following detailed description is therefore not to be taken in a limiting sense.
[0035] The various embodiments of the present invention provide a high shear mixture granulator having an improved direct drive with permanent magnet synchronous motor. The granulator comprises a granulation assembly, a power transmission assembly and an end-point monitoring assembly. The granulation assembly processes a raw material and prepare granules. The power transmission assembly transmits and regulates a transmitted power to the granulation assembly during granule preparation. The power transmission assembly comprises a permanent magnet synchronous motor (PMSM). The end-point monitoring assembly is connected to the granulated assembly and synchronizes a power transmission from the power transmission assembly. The power transmission assembly maintains a constant torque supply to the granulation assembly during a speed variation.
[0036] According to one embodiment of the present invention, the granulation assembly comprises a railing, a granulation chamber, a hopper assembly and a chopper assembly. The railing houses a vertical pendent pipe and a ladder. The granulation chamber is housed over a base platform placed adjacent to the railing. The ladder is connected to the base platform for easing an accessibility to the granulation chamber. The hopper assembly is connected to the granulator chamber. The chopper assembly is connected to the granulator chamber. A raw pharmaceutical particulate powder is inserted to the granulator chamber through
11
the vertical pendent pipe. A predetermined amount of a binder material is added to the raw pharmaceutical particle in the granulation chamber. The granulation chamber produces a required size of granules and discharges to the hopper assembly. The chopper assembly reduces a granule size to a required size during a granulation process in the granulation chamber.
[0037] According to one embodiment of the present invention, the granulation chamber comprises a bowl and a plurality of vents. The bowl is clamped to a retractable lid with a mechanical clamper. A pharmaceutical powder is charged in the bowl. The plurality of vents comprising an air vent, a binder vent and a material charging vent are placed on the lid.
[0038] According to one embodiment of the present invention, the vertical pendent pipe is attached to a control panel further comprising a human interface, a plurality of switch to control a power transmission to the granulator assembly and the end-point monitoring assembly, and a gauge for measuring a plurality of granulation parameters comprising a granule size.
[0039] According to one embodiment of the present invention, the power transmission assembly comprises a cylinder assembly and an impeller assembly. The cylinder assembly comprises a piston housed in a cylinder. The cylinder assembly is connected between the granulator chamber and the hopper assembly. The impeller assembly is connected to the to a bottom surface of the granulator chamber through a cone and a plurality of manual fastening arrangements. The impeller assembly comprises an impeller blade.
12
[0040] According to one embodiment of the present invention, the permanent magnet synchronous motor (PMSM) is fixed to the bowl with an adaptor. The PMSM is further fitted with a cooling system.
[0041] According to one embodiment of the present invention, the PMSM and the impeller blade and a hub of the impeller bade are interconnected with a connecting rod and a resting sleeve to controls a gap between the impeller blade and a bottom surface of the bowl.
[0042] According to one embodiment of the present invention, the PMSM provides a power transmission directly to the impeller blade. A feedback of transmitted power is withdrawn to monitor an end point.
[0043] According to one embodiment of the present invention, the granulator increases a power efficiency for granulation process by 13-16%.
[0044] FIG. 1 is an external view of a high shear mixture granulator depicting a self-standing equipment comprising a base frame stand (5) with a co-mill assembly (4) and a discharge hopper assembly (13). The hopper assembly (13) has an electrical connectivity established through the vertical pendent pipe (6). FIG. 2 shows a top view of the granulator shown in the FIG. 1. The orientation of the components of inside the granulator are shown in FIG. 2. FIG. 3 shows an external arrangement of a main assembly of the granulator (1) with an attached direct drive motor (PMSM) (19) and various cooling mechanisms (22) for the motor (PMSM) (19). FIG. 4 illustrates a cross-sectional details of the assembly shown in the FIG. 3. With respect to FIG. 1 - 4, granulator consists of a base platform (5) and railing (7) with a vertical pendent pipe (6) and a ladder (not
13
shown) to reach the base platform. The pharmaceutical powders are charged into the bowl (1) having an openable lid (2). A hinge and counter-weight (8) is given for tilting the lid (2). The bowl (1) and the lid (2) are clamped together with a mechanical clamper (11). The lid is further fitted with an air vent (12) to remove an air inside the bowl (1) before feeding a raw pharmaceutical powder. The lid (2) has another opening (10) for binder addition or washing water and an opening (9) for material charging. The processed granule is discharged out through a hopper assembly (13). A high speed chopper assembly (3) for the granule chopping is also provide to reduce the oversized granules.
[0045] The discharge of material is affected through a piston (15) which is operated with a pneumatically operated cylinder (14).
[0046] A removable impeller assembly (18) is held in place with the help of a cone (17) and a manual fastening arrangement (16).
[0047] A permanent magnet synchronous motor (PMSM) (19) is fixed to the bowl (1) with an adaptor (23). The PMSM (19) is fitted with a cooling system (22) which is either air cooling or a water cooling. The motor (19) and the impeller blade with its hub (18) are interconnected with a connecting rod (20) and a resting sleeve (21) to control a gap between the impeller bade (18) and a bottom surface the bowl (1).
[0048] The PMSM (19) provides the power transmission directly to the impeller blade (18) without any intermediate members and a feedback of transmitted torque is taken and monitored.
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[0049] An operator control panel (24) consisting of a human-machine Interface (25) for the operator, a plurality of production control switches (26) and gauges (27). The speed and power and torque values are directly read by an operator through the human-machine interface (25). The human-machine interface has memory unit to store a current production data for future references.
[0050] As shown in FIG. 5, the process follows a specific profile of torque and hence the power too. As per observation, the said profile remains constant for various production batches and even during scale-up to a batch with higher granule sizes.
[0051] As the impeller blade is directly (18) being operated by the PMSM (19), the values are very close to direct measurement.
[0052] The PMSM (19) have a specific torque values per ampere and does not change with different speed which provides an advantageous factor in scale-up requirements.
[0053] Table 1 shows a comparison between power consumption in the power drive of the present granulator with respect to a conventional drive.
Table 1
HSMG Model
Power (HP)
Rated current(A)
RPM ( Min.)
RPM ( Max)
No load Current (A)
Working Load (A)
Power consumed KWH
Power saved
HSMG
R2T
HSMG
R2T
HSMG
R2T
HSMG
R2T
HSMG
R2T
HSMG
R2T
HSMG
R2T
%age
300L
30
26
37
56
12
1
120
120
16
3
35
Lin
22.5
19.5
13.5
600L
50
42
64
87
11
1
105
105
19
3
55
Lin
37.5
31.5
16
1200L
100
84
123
187
8
1
78
78
28
5
95
Lin
75
63
16
15
[0054] Wherein, HSMG - Conventional High shear mixture Granulator; R2T - the new direct drive; Lin - Linear to the torque.
[0055] It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the claims.
G) ADVANTAGES OF THE INVENTION
[0056] The present high shear mixture granulator provides a high shear granulator with improved power transmission mechanism and power saving characteristics. The high shear mixture granulator further provides a direct torque feedback without any intermediate mechanical transmission elements, thus eliminates loss factors. Due to implementation of the direct drive, the present granulator is highly energy efficient and also has a reduced physical size of the power transmission assembly.
[0057] It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the claims.