Abrasive Pump for Jet Cutting with Atmospheric Hopper
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Solution Overview
Problem
Abrasive jet cutting machines face challenges in maintaining a continuous supply of abrasive particles due to the limited capacity of their small hoppers, which require frequent refilling and pressurization, leading to inefficiencies and potential abrasive loss.
Innovation Solution
An abrasive jet cutting system with an automated delivery system that uses a tank at atmospheric pressure, filled and refilled using a constant flow gas source and pneumatic components, allowing for continuous operation without the need for a large pressurized hopper, thereby preventing abrasive loss and reducing manufacturing and shipping costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large pressurized abrasive hopper is used, then continuous abrasive supply is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The system divides the abrasive supply into two separate components: a large atmospheric hopper for storage and a small pressurized delivery hopper for active use. This segmentation allows the large storage capacity without the complexity of pressurizing the entire system, resolving the contradiction between continuous supply and device complexity.
Solution Approach 2:
A pneumatic intermediary system using compressed air and valves mediates between the atmospheric hopper and the delivery nozzle. The air pressure selectively activates abrasive flow from the large hopper to the small delivery hopper, enabling continuous supply without pressurizing the main storage vessel.
2Reliability
If a large pressurized abrasive hopper is used, then continuous abrasive supply is improved, but manufacturing and shipping costs increase
Solution Approach 1:
By segmenting the hopper system into atmospheric storage and pressurized delivery components, the large hopper can be manufactured from simpler, less expensive materials without pressure containment requirements, reducing manufacturing and shipping costs while maintaining continuous supply capability.
Solution Approach 2:
The system uses a small, inexpensive pressurized delivery hopper that can be easily replaced or refilled, rather than investing in one large expensive pressurized vessel. This approach reduces overall manufacturing cost and simplifies logistics.
3Device complexity
If a small atmospheric abrasive hopper is used, then device complexity is reduced, but productivity decreases due to frequent refilling
Solution Approach 1:
The segmented hopper system allows a small delivery hopper to maintain simple device complexity while connected to a large atmospheric storage hopper that provides extended operational capacity, eliminating frequent refilling and improving productivity.
Solution Approach 2:
The large atmospheric hopper is pre-filled with abrasive material before operation begins. This preliminary action ensures that the small delivery hopper can operate continuously without frequent interruptions for refilling, improving productivity while maintaining system simplicity.
4Speed
If high air pressure is applied to force abrasive through the hose, then abrasive delivery speed is improved, but abrasive loss increases when the hopper is full
Solution Approach 1:
The system uses dynamic pneumatic control with valves that adjust air pressure application based on hopper fill level. When the delivery hopper is full, the system dynamically stops pressurization, preventing abrasive loss while maintaining high delivery speed when abrasive is needed.
Solution Approach 2:
The system incorporates feedback mechanisms that monitor the delivery hopper fill level and automatically control the pneumatic pressure application. This feedback loop ensures abrasive flows at high speed when needed and stops automatically when full, eliminating abrasive loss without sacrificing delivery 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
The system ensures a continuous supply of abrasive particles, reduces the risk of abrasive loss, lowers manufacturing and shipping costs, and eliminates the need for expensive pressurized vessels, while maintaining efficient abrasive delivery to the cutting nozzle.
Implementation Method 1
a gas source configured to pressurize the abrasive tank and convey the gas-entrained abrasive particles through the abrasive delivery tube to the nozzle
Implementation Method 2
convey the gas-entrained abrasive particles through the abrasive delivery tube
Implementation Method 3
a metering valve configured to maintain a substantially constant flow rate of the gas through the abrasive delivery tube
Implementation Method 4
a control valve configured to open or close to respectively pass or stop the gas from the gas source
Data Source
AI summary
An abrasive supply system may, for example, be used to supply abrasive particles such as garnet to a cutting nozzle of an abrasive jet cutter. According to an embodiment, the abrasive is propelled by a substantially constant flow rate gas source. According to an embodiment, the system may be supplied with abrasive from an atmospheric pressure abrasive hopper. According to an embodiment, a controller automatically actuates refilling of an abrasive tank from the abrasive hopper, and then automatically closes an abrasive supply valve and restarts abrasive propulsion. According to an embodiment, the controller may include or consist of pneumatic logic.