A kind of air floating conveying system based on gradient microporous air film

Abstract

The utility model discloses a kind of air flotation conveying systems based on gradient micropore air film, the import end of air flotation pipeline is communicated with feed pipe corresponding, feed pipe is communicated with the outlet of fan corresponding, air flotation pipeline includes multiple air flotation pipeline sections that are communicated in turn, microplate is correspondingly equipped in the bottom of each air flotation pipeline section, multiple microholes that are opened in microplate are penetrated, and the density gradient of microhole on microplate corresponding matched with multiple air flotation pipeline sections is sequentially decreased along conveying direction;The space between air cavity plate and microplate is air cavity, the air cavity matched with each air flotation pipeline section is communicated with separate gas supply module corresponding, and gas supply module includes flow guide pipe inserted into air cavity interior, and flow guide pipe is communicated with external gas source corresponding. Gradient micropore layout, separate gas supply and modular design are used in the present application, realize the low residual, low energy consumption, easy maintenance of high viscosity powder mute air flotation conveying, solve the uneven air film of traditional technology, regulation lag and mechanical wear problem.

Description

Technical Field

[0001] This utility model relates to the field of air flotation conveying pipeline technology, and in particular to an air flotation conveying system based on gradient microporous air film. Background Technology

[0002] In industrial production, the conveying efficiency of powder materials directly affects the operating costs of the production line and product quality. Pneumatic conveying technology, as a mainstream conveying method, works by using airflow to carry powder through a closed pipeline. For ordinary dry powders, conventional pneumatic conveying systems can meet basic needs. However, when encountering high-viscosity powders (such as oil-containing resin powders, hot melt adhesive particles, and intermediate products of hydrometallurgical processes), traditional technology reveals significant shortcomings: the frictional resistance between the material and the pipe wall causes powder deposition and agglomeration, with a residue rate generally exceeding 3%. Some particularly viscous materials cannot even be conveyed pneumatically. This not only results in material waste, but the cleaning of residues also leads to production line shutdowns, severely impacting continuous production.

[0003] To address the challenges of conveying viscous materials, the industry has attempted to improve traditional pneumatic conveying systems. For example, coating the inner wall of the pipe with low-friction materials such as polytetrafluoroethylene (PTFE) has been implemented. However, this approach suffers from issues such as easy coating wear, high maintenance costs, and limited effectiveness in preventing the sticking of ultrafine viscous powders. Another approach is to increase the airflow velocity, but this directly leads to a surge in energy consumption, and high-speed airflow can also exacerbate wear at pipe bends, creating a risk of dust leakage.

[0004] The tubular chain conveyor was once considered an alternative, using a mechanical chain to drive discs that circulate within a pipe to push materials. While this method can reduce the residue rate to below 1%, it has three fatal flaws: First, the chain structure means that the effective conveying section only occupies 50% of the total pipe length, with the rest occupied by the chain return stroke, doubling the equipment size and material costs; second, the mechanical transmission system generates continuous noise exceeding 85 decibels, failing to meet the environmental protection requirements of modern factories; and third, frequent malfunctions such as chain jamming and disc detachment require shutdown for maintenance on average every 200 hours, severely impacting production efficiency.

[0005] In recent years, microporous air film technology has begun to be applied in the field of air flotation conveying. By continuously releasing airflow through uniformly distributed micropores on the pipe wall, a dynamic air film is formed to isolate powder from the pipe wall. This technology can reduce the residue rate to about 2% for ordinary powders, but it still faces technical bottlenecks when processing high-viscosity materials: constant micropore density leads to a mismatch between airflow distribution and material movement, resulting in excessive airflow at the front end causing energy waste, and insufficient air film thickness at the rear end causing localized adhesion; when the material conveying volume fluctuates, the stability of the air film drops sharply, and the residue rate rises back to over 5%. These problems severely restrict the widespread application of air flotation technology in high-end manufacturing.

[0006] Therefore, it is necessary to design an air flotation transport system based on gradient microporous air film. Utility Model Content

[0007] To overcome the shortcomings of existing technologies, an air flotation transport system based on gradient microporous air film is provided.

[0008] This utility model is achieved through the following solution:

[0009] An air flotation conveying system based on gradient microporous air film includes an air flotation pipe. The inlet end of the air flotation pipe is connected to a feed pipe, and the feed pipe is connected to the outlet of a blower. The air flotation pipe includes multiple air flotation pipe sections connected in sequence. A microporous plate is provided at the bottom of each air flotation pipe section. Multiple through-holes are formed on the microporous plate. The density gradient of the micropores on the microporous plate corresponding to the multiple air flotation pipe sections decreases sequentially along the conveying direction.

[0010] An air chamber plate is provided on the outer side of the microporous plate. The space between the air chamber plate and the microporous plate is an air chamber. Each section of the air flotation pipe is matched with an air chamber and is connected to a separate air supply module. The air supply module includes a guide pipe inserted into the air chamber and is connected to an external air source.

[0011] The microporous plate is installed at the bottom of the air flotation pipe section, and the cross-section of the microporous plate is an arc of 120°.

[0012] The density gradient of the micropores on the microporous plate is divided into a front section, a middle section, and a rear section along the conveying direction, with the micropore density gradients being 200-300 pores / m in the front section, respectively. 2 100-200 boreholes / m in the middle section 2 The latter section has 50-100 holes / m 2 .

[0013] The pore size of the micropores is 0.1 to 0.3 mm.

[0014] Multiple air outlet holes are evenly provided on the guide tube.

[0015] The guide tube is connected to the internal dental endotracheal quick connector, the other end of the internal dental endotracheal quick connector is connected to the connecting tube, the connecting tube is connected to the endotracheal quick-connect elbow or endotracheal quick-connect tee, and the endotracheal quick-connect elbow or endotracheal quick-connect tee is connected to the endotracheal tube.

[0016] A chuck joint is provided at the end of the air flotation pipe section, and adjacent air flotation pipe sections are connected accordingly through the chuck joint.

[0017] Several temperature sensors and pressure sensors are installed on the air flotation pipe.

[0018] Each air supply module corresponding to the air flotation pipe section described in the section is equipped with a separate pneumatic valve.

[0019] The feed pipe is also connected to the heater, the feed pipe is connected to the outlet of the feed screw conveyor, the inlet of the feed screw conveyor is connected to the outlet of the feed hopper, and a discharge valve is provided between the outlet of the feed screw conveyor and the feed pipe.

[0020] The outlet end of the air flotation pipe is connected to the discharge pipe, and the outlet of the discharge pipe is connected to the discharge hopper.

[0021] The beneficial effects of this utility model are as follows:

[0022] 1. The air flotation conveying system of this application significantly improves the conveying efficiency of high-viscosity powders through the synergistic effect of gradient micropore layout and dynamic control technology. Traditional air flotation pipes use a uniformly distributed micropore structure, resulting in excessive airflow in the front section leading to ineffective energy consumption, and air film rupture in the rear section due to airflow attenuation. This solution sets a micropore distribution with denser micropores at the front and sparser micropores at the rear at the bottom of the air flotation pipe section. The strong air film generated by the dense micropores in the front section effectively overcomes the inertial resistance of the initial material movement, the gradually decreasing micropore density in the middle section matches the natural attenuation curve of the airflow, and the sparse micropores in the rear section maintain the necessary air film thickness while reducing excessive air supply. This gradient layout creates a dynamic balance between the airflow energy distribution and the material movement state, reducing ineffective airflow emissions by about one-third compared to conventional air flotation systems.

[0023] 2. The use of separate, split-type air supply modules solves the problem of lagging air pressure regulation in traditional technologies. Each air flotation pipe section is equipped with an independent air chamber and guide pipe, and the air supply pipeline is quickly connected via internal threaded quick-connect fittings. Pressure sensors monitor pressure fluctuations inside the air chambers of each section in real time. When a section's air pressure deviates from a set threshold, an independent pneumatic valve immediately adjusts the air intake of that section. This distributed control method avoids the "one-size-fits-all" air supply strategy of traditional open-loop systems. For example, when the delivery volume suddenly increases, the system can specifically strengthen the air pressure supply in the middle and later sections to prevent air film failure due to material accumulation in local areas. The evenly spaced air outlets on the surface of the guide pipe ensure uniform diffusion of compressed air inside the air chamber, eliminating the air pressure dead zones common in traditional air supply methods.

[0024] 3. Modular structural design significantly improves the maintainability and expandability of the equipment. The air flotation pipe sections connected by chuck joints form standardized units. During maintenance, only partial unit disassembly is needed for micro-plate cleaning or replacement, eliminating the need for a complete shutdown. The special design of the arc-shaped micro-plate allows sediment to slide off naturally under gravity. Combined with periodic reverse airflow flushing, maintenance time can be reduced to one-fifth of that of traditional tubular chain conveyors. The system supports flexible addition or reduction of pipe sections according to production line needs, and multi-path parallel expansion can be achieved through quick-connect tees on the air pipes. This flexible configuration is particularly suitable for factory renovation projects with limited space.

[0025] 4. Improved air film stability leads to a significant reduction in residue rate. The stepped air film layer formed by the gradient microporous layout creates a continuous air cushion isolation zone between the material and the pipe wall. The strong air film at the front strips away the initially sticky material clumps, the moderate air film in the middle maintains the powder suspension, and the weak air film at the rear prevents secondary adhesion of the separated material. The system dynamically adjusts the heater power based on the material state feedback from the temperature sensor, further reducing adhesion tendency by controlling the surface humidity of the powder. Under the synergistic effect of multiple factors, the system can control the residue rate of highly viscous materials containing oil and resin to within 0.5%, achieving more than six times the cleanliness of traditional pneumatic conveying systems.

[0026] 5. Energy optimization and noise control achieve dual environmental benefits. Traditional tubular chain conveyors generate structural vibration noise exceeding 85 decibels due to mechanical transmission. This system, with its pure pneumatic conveying method, reduces operating noise to below 65 decibels, meeting the quiet standards of precision electronics workshops. The gradient microporous structure reduces ineffective airflow emissions, and combined with a segmented air supply strategy based on demand, the overall air consumption is reduced by about one-quarter compared to conventional air flotation systems. The arc-shaped microporous plate design allows airflow to enter the conveying pipe at a tangential angle, forming a spiral airflow field. This flow field shape not only enhances the material suspension effect but also reduces energy loss by reducing the frontal impact of airflow on the pipe wall.

[0027] 6. Temperature adaptability expands the system's application range. The heater integrated into the feed pipe allows for precise temperature control of the conveying airflow. It maintains ambient temperature when handling heat-sensitive materials and appropriately increases the airflow temperature when dealing with easily crystallizing materials. The linkage control between the temperature sensor and the air supply system ensures real-time matching of the air film strength with the material state. For example, when conveying low-temperature, easily agglomerated materials, the system automatically increases the temperature of the front-end air chamber to prevent condensation and blockage of micropores. This multi-parameter coordinated control mechanism enables the system to stably handle semi-wet materials with a moisture content of less than 8%, overcoming the limitation of traditional air flotation technology being only suitable for dried powders.

[0028] 7. Traditional tubular chain conveyors require maintenance every 200 hours on average, while this system's contactless conveying method completely eliminates the risk of mechanical wear. When individual micro-holes become blocked, the system uses pressure sensors to locate the faulty pipe section, and with the help of quick-release chuck couplings, the unit can be replaced within ten minutes. Attached Figure Description

[0029] Figure 1 This is a system block diagram of an air flotation conveying system based on a gradient microporous air film according to the present invention;

[0030] Figure 2 This is a perspective view of one section of an air flotation pipeline in an air flotation conveying system based on a gradient microporous air film according to this utility model.

[0031] Figure 3 for Figure 2 A sectional view;

[0032] Figure 4 This is a front view of another section of the air flotation pipe in the air flotation conveying system based on gradient microporous air film according to this utility model.

[0033] Figure 5 for Figure 4 A cross-sectional view along the AA direction;

[0034] Figure 6 This is a schematic diagram of the flow guide tube.

[0035] Figure 7 for Figure 6 Cross-sectional view along the BB direction;

[0036] In the diagram: 1 is the feed pipe, 2 is the blower, 3 is the temperature sensor, 4 is the chuck connector, 5 is the air supply module, 51 is the guide pipe, 52 is the air outlet, 53 is the internal thread quick-connect air pipe, 54 is the connecting pipe, 55 is the quick-connect elbow to the air pipe, 56 is the quick-connect tee to the air pipe, 57 is the air pipe, 6 is the air flotation pipe, 61 is the air flotation pipe section, 62 is the air chamber, 63 is the microporous plate, 64 is the micropore, 65 is the air chamber plate, 7 is the pressure sensor, 8 is the pneumatic valve, 9 is the heater, 10 is the feed screw conveyor, 11 is the feed hopper, 12 is the discharge valve, 13 is the discharge pipe, and 14 is the discharge hopper. Detailed Implementation

[0037] The present invention will be further described below with reference to the accompanying drawings and specific embodiments:

[0038] like Figure 1 As shown, an air flotation conveying system based on a gradient microporous air film includes an air flotation pipe 6. The inlet end of the air flotation pipe 6 is connected to a feed pipe 1, and the feed pipe 1 is connected to the outlet of a blower 2. Figure 2 , 3As shown, the air flotation pipe 6 includes multiple air flotation pipe sections 61 connected in sequence, such as... Figure 4 , 5 As shown, a microporous plate 63 is provided at the bottom of each section of the air flotation pipe 61. Multiple through-holes 64 are formed on the microporous plate 63. The density gradient of the micropores 64 on the microporous plate 63 corresponding to multiple sections of the air flotation pipe 61 decreases sequentially along the conveying direction. An air chamber plate 65 is provided on the outside of the microporous plate 63. The space between the air chamber plate 65 and the microporous plate 63 is an air chamber 62. The air chamber 62 matched to each section of the air flotation pipe 61 is connected to a separate air supply module 5. The air supply module 5 includes a guide pipe 51 inserted into the air chamber 62. The guide pipe 51 is connected to an external air source.

[0039] The microporous plate 63 is disposed at the bottom of the air flotation pipe section 61, and the cross-section of the microporous plate 63 is an arc shape of 120°. The density gradient of the micropores 64 on the microporous plate 63 is divided into a front section, a middle section, and a rear section along the conveying direction, with the micropore density gradient being 200-300 pores / m in the front section. 2 100-200 boreholes / m in the middle section 2 The latter section has 50-100 holes / m 2 The pore size of the micropore 64 is 0.1–0.3 mm.

[0040] like Figure 6 , 7 As shown, a plurality of air outlet holes 52 are evenly provided on the guide tube 51. The guide tube 51 is connected to the internal thread quick-connect endotracheal connector 53, the other end of the internal thread quick-connect endotracheal connector 53 is connected to the connecting tube 54, the connecting tube 54 is connected to the quick-connect elbow 55 or quick-connect tee 56, and the quick-connect elbow 55 or quick-connect tee 56 is connected to the endotracheal tube 57.

[0041] A chuck connector 4 is provided at the end of each air flotation pipe section 61, and adjacent air flotation pipe sections 61 are connected accordingly via the chuck connector 4. Several temperature sensors 3 and pressure sensors 7 are correspondingly provided on the air flotation pipe 6. Each air supply module 5 corresponding to each air flotation pipe section 61 is equipped with a separate pneumatic valve 8.

[0042] In this embodiment, the pressure drop of each section of the pipeline is monitored in real time by a pressure sensor, and the air supply pressure (0.2~0.5MPa) and flow rate of the air chamber are dynamically adjusted. The specific adjustment principle and process are well-known technologies and will not be described in detail here.

[0043] However, in this embodiment, the control logic is as follows:

[0044] Qi=K·(△Pi / △Pmax)·Qbase

[0045] Where Qi is the flow rate of the i-th gas chamber, ΔPi is the real-time pressure drop, Qbase is the base flow rate, and K is the viscosity correction factor (1.0~2.0). Specifically...

[0046] The feed pipe 1 is also connected to the heater 9. The feed pipe 1 is connected to the outlet of the feed screw conveyor 10. The inlet of the feed screw conveyor 10 is connected to the outlet of the feed hopper 11. A discharge valve 12 is provided between the outlet of the feed screw conveyor 10 and the feed pipe 1. The outlet end of the air flotation pipe 6 is connected to the discharge pipe 13. The outlet of the discharge pipe 13 is connected to the discharge hopper 14.

[0047] This application achieves quiet air flotation conveying of high-viscosity powders with low residue, low energy consumption, and easy maintenance through gradient micropore layout, split closed-loop air supply, and modular design, solving the problems of uneven air film, lag in adjustment, and mechanical wear in traditional technologies.

[0048] The working process of this air flotation conveying system is as follows:

[0049] Starting with material storage in the feed hopper, the feed screw conveyor steadily pushes the powder material into the feed pipe. During this process, the heater regulates the temperature of the conveying airflow according to the material characteristics, and reduces the adhesion tendency by controlling the surface humidity of the powder. After the airflow generated by the blower mixes with the material in the feed pipe, they enter the main conveying channel, which consists of multiple air flotation pipe sections connected in series.

[0050] At the bottom of each section of the air flotation pipe, an arc-shaped microporous plate is installed, with the density of micropores on its surface decreasing regularly along the conveying direction. This gradient distribution design takes into account the attenuation characteristics of airflow within the pipe. The dense micropores in the front section form a thicker air film to overcome the initial inertia of the material, while the sparse micropores in the rear section maintain the necessary air film thickness to prevent secondary adhesion. A sealed air cavity is formed on the outside of the microporous plate through an air chamber plate. Compressed air is introduced into the air cavity through a guide pipe, and pressure equalization is achieved through evenly distributed air outlets, ultimately forming a continuous and stable air film layer from the micropores.

[0051] The system adopts a modular air supply design, with each air flotation pipe section equipped with an independent air supply unit. The guide pipe connects to an external air source via internal threaded quick-connect fittings, and uses quick-connect elbows and tees to connect multiple pipe sections. Chuck fittings enable quick-sealing connections between adjacent air flotation pipe sections, ensuring the scalability of the overall piping system. Pressure sensors monitor the internal pressure of each section's air chamber in real time, and combined with material status feedback from temperature sensors, independent pneumatic valves dynamically adjust the air supply to each section.

[0052] When the material reaches the end of the pipeline, the airflow velocity naturally decreases, and the powder falls into the discharge hopper through the discharge pipe under the influence of gravity. During system maintenance, the air flotation pipeline section can be quickly separated by disassembling the chuck joint, and efficient cleaning can be performed using the arc-shaped structure of the microporous plate.

[0053] In this embodiment, the material propulsion principle of the screw conveyor, the basic function of the fan in generating conveying airflow, and the standard storage structure of the silo; the signal acquisition methods of the temperature and pressure sensors and the switching control principle of the pneumatic valve belong to general industrial control technology; the sealing connection method of the quick-connect fitting for the air pipe and the mechanical structure of the chuck joint belong to existing pipeline connection technology. All of the above are well-known technologies and will not be described in detail here.

[0054] This patent enables dynamic adjustment of gas supply parameters based on real-time pressure drop and material viscosity, reducing energy consumption by 15% to 20%. See Table 1 for details.

[0055] Table 1 Performance Comparison

[0056] index Traditional air flotation pipeline This invention Pressure drop (kPa / m) 3.5 1.2～1.5 Residual rate (%) 2.1 0.3～0.5 Energy consumption (kW·h / t) 18.75 15.0

[0057] The core innovation of this technical solution lies in combining a gradient micropore layout with individual control. The former optimizes airflow distribution efficiency, while the latter solves the problem of lag in air pressure regulation in traditional systems. First, the gradient micropore layout matches the natural attenuation curve of the airflow. The dense micropores in the front section compensate for initial velocity loss, while the sparse micropores in the rear section avoid excessive energy consumption, saving approximately one-quarter of energy compared to a uniform micropore design. Second, segmented independent air supply allows the air film thickness in each section to be dynamically adjusted according to the real-time state of the material, controlling the residual rate of sticky powder to below 0.5%. Third, the modular pipeline structure increases the system's scalability by more than three times; maintenance only requires disassembling a local air flotation pipeline section, significantly reducing equipment downtime. Compared to traditional tubular chain conveyors, the system's operating noise is reduced to below 65 decibels, with an effective conveying section accounting for over 95%, making it particularly suitable for fine chemical production scenarios requiring a clean environment.

[0058] Although the technical solutions of this utility model have been described and enumerated in detail, it should be understood that modifications to the above embodiments or the adoption of equivalent alternatives are obvious to those skilled in the art. Such modifications or improvements made without departing from the spirit of this utility model are all within the scope of protection claimed by this utility model.

Claims

1. An air flotation conveying system based on gradient microporous air film, comprising an air flotation pipe (6), wherein the inlet end of the air flotation pipe (6) is connected to a feed pipe (1), and the feed pipe (1) is connected to the outlet of a blower (2), characterized in that: The air flotation pipe (6) includes multiple air flotation pipe sections (61) connected in sequence. At the bottom of each air flotation pipe section (61), a microporous plate (63) is provided. Multiple through microholes (64) are opened on the microporous plate (63). The density gradient of the microholes (64) on the microporous plate (63) that corresponds to and matches the multiple air flotation pipe sections (61) decreases sequentially along the conveying direction. An air chamber plate (65) is provided on the outside of the microporous plate (63). The space between the air chamber plate (65) and the microporous plate (63) is an air chamber (62). Each section of the air flotation pipe (61) is matched with an air chamber (62) that is connected to a separate air supply module (5). The air supply module (5) includes a guide pipe (51) inserted into the air chamber (62). The guide pipe (51) is connected to an external air source.

2. The air flotation conveying system based on gradient microporous air film according to claim 1, characterized in that: The microporous plate (63) is disposed at the bottom of the air flotation pipe section (61), and the cross-section of the microporous plate (63) is an arc of 120°.

3. The air flotation conveying system based on gradient microporous air film according to claim 1, characterized in that: The density gradient of the micropores (64) on the microporous plate (63) is divided into a front section, a middle section, and a rear section along the conveying direction, with the micropore density gradients being 200-300 pores / m in the front section. 2 100-200 boreholes / m in the middle section 2 The latter section has 50-100 holes / m 2 ; The pore size of the micropore (64) is 0.1 to 0.3 mm.

4. The air flotation conveying system based on gradient microporous air film according to claim 1, characterized in that: Multiple air outlets (52) are uniformly provided on the guide tube (51).

5. The air flotation conveying system based on gradient microporous air film according to claim 1, characterized in that: The guide tube (51) is connected to the internal thread quick-connect trachea connector (53), the other end of the internal thread quick-connect trachea connector (53) is connected to the connecting tube (54), the connecting tube (54) is connected to the quick-connect elbow (55) or quick-connect tee (56), and the quick-connect elbow (55) or quick-connect tee (56) is connected to the trachea (57).

6. The air flotation conveying system based on gradient microporous air film according to claim 1, characterized in that: A chuck connector (4) is provided at the end of the air flotation pipe section (61), and adjacent air flotation pipe sections (61) are connected accordingly through the chuck connector (4).

7. The air flotation conveying system based on gradient microporous air film according to claim 1, characterized in that: Several temperature sensors (3) and pressure sensors (7) are respectively installed on the air flotation pipe (6).

8. The air flotation conveying system based on gradient microporous air film according to claim 1, characterized in that: Each air supply module (5) corresponding to each air flotation pipe section (61) is equipped with a separate pneumatic valve (8).

9. The air flotation conveying system based on gradient microporous air film according to claim 1, characterized in that: The feed pipe (1) is also connected to the heater (9). The feed pipe (1) is connected to the outlet of the feed screw conveyor (10). The inlet of the feed screw conveyor (10) is connected to the outlet of the feed hopper (11). A discharge valve (12) is provided between the outlet of the feed screw conveyor (10) and the feed pipe (1).

10. The air flotation conveying system based on gradient microporous air film according to claim 1, characterized in that: The outlet end of the air flotation pipe (6) is connected to the discharge pipe (13), and the outlet of the discharge pipe (13) is connected to the discharge hopper (14).

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