Angled Plate Separator for Vacuum Die Casting Gas Cleaning
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Solution Overview
Problem
In vacuum-assisted high-pressure die casting, the removal of air and gases from the mold cavity can lead to the introduction of casting material and lubricant residues into the vacuum system, causing clogging and damage to valves and pumps, resulting in frequent maintenance and production downtime.
Innovation Solution
A separator with a separation chamber containing angled plates that deflect particles out of the gas flow, allowing clean gas to pass through while collecting particles at the bottom, eliminating the need for filters and reducing maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a vacuum pump is used to remove air and gases from the mold cavity, then porosity is reduced and surface finish is improved, but casting material and lubricant residues enter the vacuum system causing clogging and damage
Solution Approach 1:
The separator acts as an intermediary device positioned between the mold cavity and the vacuum pump. It intercepts and removes casting material and lubricant residues from the gas stream before the contaminants can reach and damage the vacuum pump, thereby protecting the vacuum system while maintaining effective vacuum-assisted casting
2Object-affected harmful factors
If conventional filters are used in the flow lines, then particles are separated from the gas, but the filters become clogged quickly and require frequent replacement
Solution Approach 1:
The separator extracts and removes the harmful casting material and lubricant residues from the gas stream using a design that allows continuous operation. By taking out the contaminants through a collection chamber at the bottom rather than through a filtering medium, the system avoids the clogging problem that plagues conventional filters, eliminating the need for frequent replacements and reducing production downtime
3Object-affected harmful factors
If other separators with filters or particle retainers are used, then particles are separated, but the filters fill up over time requiring regular cleaning or replacement
Solution Approach 1:
The separator extracts particles from the gas stream and collects them in a bottom chamber without using filters or particle retainers that would require cleaning or replacement. The design allows particles to be continuously removed from the system through an opening in the bottom chamber, eliminating maintenance time associated with filter replacement
Solution Approach 2:
The separator design allows for easy self-service maintenance where the collection chamber can be quickly opened and emptied of accumulated particles. This simple maintenance approach minimizes downtime and allows the system to remain operational with minimal intervention
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
The separator effectively prevents particle accumulation in the vacuum system, reducing downtime and extending the life of valves and pumps by ensuring continuous airflow without clogging, thus improving the quality of cast parts and reducing maintenance needs.
Implementation Method 1
the one or more obstacles comprise a first plate being arranged in the direct flow path of the gas entering the separation chamber via the inflow and being arranged at an angle compared to the direction of the flow path of the gas entering the separation chamber via the inflow such that the particles are at least in part collected at a bottom portion of the separation chamber
Data Source
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AI summary
The invention inter alia pertains to a separator for a vacuum assisted die casting system, the separator (1) comprising an inflow (2) for a gas (8) to be cleaned, an outflow (4) for the cleaned gas (8) and a separation chamber (6) between the inflow (2) and the outflow (4) for cleaning the gas, wherein the separation chamber (6) comprises one or more obstacles (12, 14, 16) in the flow path from the inflow (2) to the outflow (3) for separating particles (10) from the gas (8), wherein the one or more obstacles (12, 14, 16) comprise a first plate (12) being arranged in the direct flow path of the gas entering the separation chamber (6) via the inflow (2) and being arranged at an angle (α) compared to the direction (A) of the flow path of the gas (8) entering the separation chamber (6) via the inflow (2) such that the particles (10) are at least in part collected at a bottom portion (18) of the separation chamber (6).