Blender Discharge Baffle and Automated Cleaning System
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Solution Overview
Problem
Blenders used in material processing face challenges with accurately mixing and handling low bulk density materials like regrind flake, require frequent manual cleaning which is hazardous and can lead to production issues due to moisture content changes during processing.
Innovation Solution
A discharge system with a baffle and feeder mechanism that forces material downward through the outlet, combined with a mixing chamber and level sensor for precise material control, and cleaning air jets or ultrasonic actuators for automated cleaning, along with a system to manage moisture content using heaters and sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual cleaning is performed to remove raw materials from the blender chamber, then production setup for new batches is enabled, but worker safety is compromised and damage to other machinery may occur
Solution Approach 1:
The system performs cleaning automatically without human intervention. The blender chamber is equipped with automated cleaning mechanisms that remove raw materials and residues after each batch, enabling the system to clean itself and eliminating the need for workers to manually access elevated locations
Solution Approach 2:
Manual mechanical cleaning operations are replaced with automated mechanical cleaning systems. The system uses automated mechanisms such as scrapers, blowers, or washing systems to remove materials from the chamber, replacing the need for manual labor in hazardous locations
2Manufacturing precision
If dryers are provided upstream to dry raw materials, then initial moisture content is controlled, but moisture content increases during delivery through the blender due to ambient air contact
Solution Approach 1:
The blender chamber is maintained under a controlled atmosphere, typically using inert gas (such as nitrogen) or dried air to displace ambient moisture-containing air. This prevents moisture transfer from the atmosphere to the hygroscopic raw materials during the blending process
Solution Approach 2:
The system controls the moisture content by changing the atmospheric parameters within the blender chamber. By controlling temperature, humidity, and gas composition in the chamber, the system prevents moisture absorption by materials during processing
3Volume of moving object
If the blender is located in elevated and inaccessible positions, then space utilization is improved, but cleaning becomes hazardous and access difficult
Solution Approach 1:
The elevated blender chamber is equipped with automated cleaning systems that eliminate the need for human access during cleaning operations. Mechanical scrapers, air blowers, or washing systems are integrated into the chamber to perform cleaning automatically, making the location's inaccessibility irrelevant to the cleaning process
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
Enhances the mixing and feeding of low bulk density materials, improves safety by reducing manual cleaning hazards, and maintains consistent moisture levels, thereby improving production quality and efficiency.
Implementation Method 1
the baffle has at least one opening therein to allow through-passage of material on the one hand but to exert downward pressure on material being fed to the outlet thus forcing the material downward through the outlet
Implementation Method 2
a system to manage moisture content using heaters and sensors
Implementation Method 3
cleaning air jets or ultrasonic actuators for automated cleaning
Data Source
AI summary
A blender has a mixing chamber for reception of materials to be blended. A mixing screw is mounted at a bottom of the mixing chamber for mixing materials within the mixing chamber and delivering mixed materials to an outlet feeding a processing line. The blender has a plurality of material handling compartments. One or more cleaning air jets are provided in each material handling compartment. The cleaning air jets are operable to direct material towards an outlet of the compartment. Each cleaning air jet is connected to a pressurised air supply through a valve which controls delivery of pressurised air to the cleaning air jet.