Air Classifier Kinked Conveyor Belt Separation
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Solution Overview
Problem
Existing air classifiers face inefficiencies in separating lighter materials, such as plastic films, from material mixtures on conveyor belts due to these materials adhering to the belt and being inadequately lifted by the air flow, resulting in a low separation efficiency.
Innovation Solution
The air classifier incorporates height-adjustable solid walls and a kinked conveyor belt design, allowing larger constituents to pass through and enabling a more effective air flow to lift lighter materials by guiding the conveyor belt to change direction sharply, ensuring that lighter materials are separated before heavier ones, and utilizing a suction fan with a hood-like housing and sensor flap for enhanced separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the conveyor belt runs straight without bends, then the structure is simple and easy to manufacture, but the air flow cannot effectively lift lighter materials from the material mixture
Solution Approach 1:
The conveyor belt is designed with a bend (curved section) instead of running straight. This curvature causes the material mixture to lift off the belt surface, creating a gap that allows air flow to penetrate underneath and effectively lift lighter materials. The curved path transforms the separation mechanism from surface-level airflow to multi-directional airflow including upward and downward components.
Solution Approach 2:
The conveyor belt transition from horizontal to inclined section introduces a new spatial dimension to the separation process. By changing the belt angle, the material mixture is lifted into a different spatial plane, allowing air flow to attack the material from multiple directions (below, above, and sideways) rather than just horizontally from above.
2Productivity
If the air flow attacks only the upper surface of the material mixture, then the device structure is simple, but lighter materials adhering to the belt cannot be effectively separated
Solution Approach 1:
The bent conveyor belt configuration enables air flow to attack the material mixture from multiple directions. The curved path allows air to penetrate below the material layer, creating upward lift forces that separate lighter materials adhering to the belt surface, in addition to the conventional downward airflow.
Solution Approach 2:
The air flow separation process is divided into multiple zones: a first section where air attacks the upper surface of the material mixture, and a second section after the bend where air flow attacks from below and sideways. This segmentation allows each air flow zone to perform a specific separation function, improving overall efficiency.
3Productivity
If heavier materials are positioned above lighter materials in the material mixture, then the material distribution is random, but lighter materials cannot be separated by airflow due to being covered
Solution Approach 1:
The first classifier stage performs preliminary separation of the material mixture before it reaches the second stage. This pre-separation arranges materials in a favorable configuration (lighter materials on top, heavier materials below) that enables the second air classifier to operate more effectively. The preliminary action eliminates the need for complex real-time sorting mechanisms.
Solution Approach 2:
The classification process is divided into two sequential stages: a first air classifier that performs initial separation and arrangement of materials, and a second air classifier that performs the main separation task. This segmentation allows each stage to specialize in a specific separation function, with the first stage preparing the material distribution for optimal second stage performance.
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 configuration significantly increases the separation efficiency of lighter materials, ensuring they are lifted and separated from heavier materials, improving the overall separation process and allowing for more effective pre-separation of fractions in the first sifter stage, enhancing the synergy between separation stages.
Implementation Method 1
a blower (7) is indicated above the bend (5), which generates an upward airflow (indicated by arrows) that transports lighter material (8) upwards from the material mixture (3)
Implementation Method 2
Due to the conveyor belt's speed, the material mixture (3) briefly lifts off the conveyor belt (2) just beyond the bend (5) before resting on the conveyor belt (2) again in the second section (6)
Data Source
Figure 1
AI summary
In an air classifier (1) with a conveyor belt (2) conveying a material mixture (3) and a blower (7) generating an upward flow of air from the conveyor belt (2) and transporting lighter material (8) upwards from the material mixture (3), the invention proposes that the conveyor belt (2) has a first section (4) which runs in a first plane, and a second section (6) which is arranged behind the first section (4) in the conveying direction and which runs in a plane further downwards compared to the first section (4), wherein the area of the transition from the first section (4) to the second section (6) is designed as a kink (5).