Adjustable Air Flow Limiter for Resin Conveying
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Solution Overview
Problem
Current pneumatic plastic resin pellet conveying systems face challenges in maintaining consistent air flow control and conveying speed, leading to potential damage to pellets and system inefficiencies, particularly when using a single large vacuum pump to serve multiple receivers.
Innovation Solution
The implementation of an adjustable air flow limiter at each receiver or the vacuum pump suction inlet ensures a constant standard cubic feet per minute (SCFM) air flow, allowing for the use of a single large vacuum pump without risking excessive velocity, and eliminates the need for central control systems by enabling each receiver to control its own operation based on local conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single large vacuum pump is used to serve multiple receivers, then system cost is reduced and simplicity is improved, but air flow control consistency deteriorates and excessive velocity may damage pellets
Solution Approach 1:
The system divides the air flow control function into separate segments at each receiver location. Each receiver has its own air flow limiter that independently controls air flow, allowing the single large vacuum pump to serve multiple receivers without compromising control consistency. This segmentation resolves the contradiction by distributing control functions locally rather than requiring centralized complex control.
Solution Approach 2:
An air flow limiter acts as an intermediary device between the vacuum pump and each receiver. This intermediary component regulates air flow to maintain consistent velocity, preventing direct uncontrolled air flow from the large vacuum pump while still allowing the simplified single-pump configuration to operate effectively.
2Productivity
If air flow velocity is increased to maximize throughput, then productivity is improved, but pellet damage increases due to excessive velocity
Solution Approach 1:
The air flow limiter dynamically adjusts air flow parameters (velocity, volume) to maintain optimal conveying conditions. By controlling the air flow rate and velocity parameters, the system achieves maximum throughput while keeping pellet velocity within safe limits, thus resolving the contradiction between productivity and pellet integrity.
3Adaptability or versatility
If air flow is not limited at each receiver, then system operation flexibility is improved, but excessive air dumping occurs reducing system vacuum levels and throughput
Solution Approach 1:
Each receiver is equipped with its own air flow limiter that automatically regulates air flow based on local conditions. This self-service approach maintains system flexibility while preventing excessive air dumping, as each receiver independently manages its own air flow to contribute to overall system throughput rather than creating conflicts.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution reduces system costs, enhances consistency in air flow delivery, allows for easy expansion, and prevents excessive air dumping, ensuring the resin pellets are conveyed within a safe velocity range, thus minimizing damage and system downtime.
Implementation Method 1
suction created by operation of the vacuum pump draws granular plastic resin from the supply into the receivers
Implementation Method 2
suction created by operation of the vacuum pump draws granular plastic resin from the supply
Implementation Method 3
upward air flow through the tube
Implementation Method 4
sail assembly positioned in the tube and moveable therewithin responsively to air flow through the tube
Data Source
AI summary
Method and apparatus for air flow limiting comprise a vertically oriented tube, a sail assembly positioned in the tube and moveable therewithin responsively to air flow through the tube to limit rate of air flow through the tube and halt air flow through the tube upon air flow rate through the tube exceeding a preselected value, and a moveable stop for adjustably changing the length of travel of the sail assembly thereby changing the maximum amount of air flow.