Auger and Cutting Disc Device for Uniform Vegetable Mincing
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Solution Overview
Problem
Current mincing and mixing systems for animal feed and biogas plants are inefficient, consuming excessive energy, causing machinery wear, and incurring high maintenance and labor costs due to the need for large product sizes and complex adaptations, with existing solutions offering minimal improvements.
Innovation Solution
A device that combines fine mincing and cutting functions in a single unit, featuring a low-speed mixing auger and high-speed cutting discs with a separating mechanism, allowing for efficient chopping of materials to less than 1 cm, reducing energy consumption and minimizing wear by expelling unwanted objects, and incorporating a resend tube for recirculation and homogenization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high pressure is applied on the augers to mix and move products, then mixing and transport function is achieved, but energy consumption increases significantly and product uniformity deteriorates
Solution Approach 1:
The device segments the processing function into two distinct cavities: a mixing cavity for gentle mixing and a mincing cavity for size reduction. This segmentation allows each cavity to perform its specific function optimally without the negative effects of high pressure, achieving both energy savings and product uniformity.
Solution Approach 2:
The patent introduces an intermediary mechanism (the separating part with slots and the specific arrangement of cutting discs) that allows material to pass from the mixing cavity to the mincing cavity without requiring high pressure. This intermediary enables the transition between mixing and size reduction functions while maintaining low energy consumption.
2Loss of energy
If the size of augers is reduced to decrease wear and power consumption, then machinery wear decreases and energy consumption reduces, but processing time increases significantly
Solution Approach 1:
The device separates the processing functions into two cavities with different mechanisms: the mixing cavity uses a large-diameter auger for efficient mixing, while the mincing cavity uses high-speed cutting discs for rapid size reduction. This segmentation allows each component to be optimized for its specific function, maintaining high productivity while reducing overall energy consumption and wear.
Solution Approach 2:
The patent merges the mixing and mincing functions into a single integrated device with two cavities. The mixing cavity prepares the material efficiently, and the mincing cavity processes it rapidly, combining the advantages of both functions in one system to achieve high productivity without excessive energy consumption.
3Manufacturing precision
If independent mincing machines are used before mixing carts to achieve small particle sizes, then cutting precision is improved, but device complexity and adaptation requirements increase significantly
Solution Approach 1:
The patent combines the mixing and mincing functions into a single integrated device with two cavities. The mixing cavity prepares the material, and the mincing cavity processes it to the required size, eliminating the need for separate independent machines and reducing system complexity while maintaining cutting precision.
Solution Approach 2:
The device is designed as a multi-functional unit that can perform both mixing and mincing operations. The mincing cavity can be adapted to handle various products (straw, vegetables, carrots, beet, corn cane) by changing cutting discs, providing universality without requiring completely different machines for each product type.
4Productivity
If cutting discs rotate at high speed to achieve fine mincing, then productivity is improved, but damage to cutting discs increases
Solution Approach 1:
The patent extracts the cutting discs from direct contact with the bulk material by introducing a separating part with slots. The cutting discs only contact material that passes through the slots, reducing the overall load and damage while maintaining high rotation speed for fine mincing of the extracted material.
Solution Approach 2:
The separating part with slots acts as an intermediary between the mixing cavity and the cutting discs. It controls the flow of material to the cutting discs, allowing them to process only the material that passes through the slots, thereby reducing damage while maintaining high-speed operation for productivity.
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 device achieves significant energy savings, reduces machinery wear, and enhances production efficiency by allowing for faster processing of large volumes with uniformity and reduced pressure on augers, while effectively handling varied products and impurities.
Implementation Method 1
A mixing cavity or hopper with an auger that rotates at low revs, the purpose of which is to mix the products and to ensure they circulate to enter a mincing and cutting cavity
Implementation Method 2
A mincing and cutting cavity with a shaft that rotates at high speeds and on which a series of cutting discs are mounted
Implementation Method 3
Once the material has been chopped and has crossed the separating part, it falls into the chopped or sliced material cavity by gravity
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
This device comprises: a mixing cavity or hopper (7) that has at least one auger (1) that rotates at low revolutions; a mincing and cutting cavity (11) alongside the hopper (7) and that has a mincing or cutting shaft (2) that turns at high speed and on which are mounted a series of cutting discs (12) and a disc (5) for entraining the minced product; a separator element (3) arranged in the area of contact between the mixing hopper (7) and the cutting or mincing cavity (11); and means for emptying out the cut or minced mixture from inside the cutting or mincing cavity (11).