Air Flow Limiter with Closed-Open Sensing for Pneumatic Conveying
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Solution Overview
Problem
Current pneumatic plastic resin pellet conveying systems face challenges in maintaining consistent air flow rates and conveying speeds, 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 air flow limiters at each receiver or the vacuum pump suction inlet to regulate and maintain a constant standard cubic feet per minute (SCFM) air flow rate, allowing for the use of a single large vacuum pump without risking excessive velocity or vacuum loss, and enabling simultaneous loading of multiple receivers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single large vacuum pump is used to serve multiple receivers, then system productivity and efficiency are improved, but air flow rate becomes inconsistent and conveying speed becomes excessive causing pellet damage
Solution Approach 1:
The patent divides the air flow control into separate segments by installing individual air flow limiters at each receiver or receiver group. This segmentation allows each receiver to have controlled air flow independently, preventing excessive velocity that damages pellets while maintaining high overall system productivity through the use of a single large vacuum pump.
Solution Approach 2:
The patent applies local quality control by positioning air flow limiters at specific locations (each receiver or receiver group) rather than uniformly throughout the system. This allows tailored air flow regulation for different conveying distances and receiver requirements, ensuring optimal conveying speed that prevents pellet damage while maintaining system efficiency.
2Productivity
If air flow rate is increased to maximize throughput, then productivity is improved, but vacuum levels drop and resin material is lost
Solution Approach 1:
The air flow limiter incorporates a detector that monitors air flow conditions and provides feedback control. When the detector senses that air flow is pulling only air without resin material (indicating excessive flow and vacuum loss), it signals the air flow limiter to reduce flow, thereby maintaining stable vacuum levels and preventing resin material loss while preserving throughput capability.
3Productivity
If air flow velocity is increased to reduce conveying time, then productivity is improved, but pellets are damaged due to excessive speed
Solution Approach 1:
The patent changes the air flow velocity parameter dynamically by using adjustable air flow limiters that can be tuned to optimal conveying speeds for different pellet types and conveying distances. This allows the system to maintain high productivity through efficient conveying while preventing pellet fracture by keeping velocity within safe parameters.
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 ensures consistent and controlled air flow, reducing the risk of pellet damage and system inefficiencies, allowing for the use of high-horsepower vacuum pumps while maintaining desired vacuum levels and preventing air dumping, thus enhancing the reliability and efficiency of the conveying system.
Implementation Method 1
an emitter-detector combination to provide and detect an electromagnetic beam
Implementation Method 2
a vacuum pump or pumps... The suction moves large quantities of air which carries thermoplastic resin pellets through the 'vacuum' line
Data Source
AI summary
Method and apparatus for air flow regulation comprise a vertically oriented tube, a sail assembly positioned in the tube and moveable therewithin responsively to air flow through the tube to regulate rate of air flow through the tube and to stop air flow through the tube upon air flow rate through the tube exceeding a preselected value with a detector for sensing when the sail assembly has stopped air flow through the tube as a result of air flow rate exceeding said pre-selected value.