Breaker Plate Cutting Chambers for Clogging Prevention
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Solution Overview
Problem
Inhomogeneous biological raw materials with significant strength differences cause uneven processing in knife-perforated disc systems, leading to material accumulation, clogging, and disruptions in the cutting process due to differential crushing and drainage properties.
Innovation Solution
The integration of cutting chambers on the perforated disc surface, radially distributed to redirect solid raw material portions back into the main cutting process, ensuring continuous processing and additional cutting, thereby improving the cutting conditions and preventing clogging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If knife-perforated disc systems process inhomogeneous biological raw materials with significant strength differences, then the cutting process is disrupted, but processing capability is maintained
Solution Approach 1:
The working surface of the perforated disc is segmented into multiple functional zones: an outer annular region with first groups of cutting chambers for initial processing of solid material portions, and an inner region with second groups of cutting chambers for final processing. This segmentation allows different material portions to be processed in different zones, preventing clogging and maintaining continuous operation.
Solution Approach 2:
Cutting chambers act as intermediary structures between the knife and the discharge path. These chambers receive solid material portions that cannot be directly processed by the knife-perforated disc system, perform additional cutting within the chambers, and then discharge the processed material back into the main cutting process, thereby mediating the disruption caused by inhomogeneous raw materials.
2Reliability
If solid raw material portions accumulate in front of the knife, then material buildup occurs and clogging increases, but cutting function is maintained
Solution Approach 1:
The cutting chambers are designed to receive and process the harmful material accumulations that build up in front of the knife. By providing dedicated chambers for these solid portions, the system converts the harmful clogging effect into a beneficial additional cutting process, where the chambers perform repeated cutting on material that would otherwise disrupt the main cutting function.
Solution Approach 2:
The cutting chambers provide a different processing environment compared to the main knife-perforated disc interface. Within the chambers, material undergoes repeated cutting with changing geometric parameters as it interacts with the chamber walls and is discharged back into the central area, effectively changing the processing parameters for difficult-to-cut solid portions.
3Reliability
If solid material portions are ejected to improve quality, then disruptive fractions are removed, but processing continuity is reduced
Solution Approach 1:
Instead of requiring external ejection mechanisms to remove disruptive material fractions, the cutting chambers perform self-service by processing the solid material portions internally. The chambers automatically receive, cut, and discharge material back into the main process, eliminating the need for separate ejection systems and maintaining continuous processing while improving material quality.
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 design ensures continuous processing of solid raw material portions, maintaining disc cleanliness, improving drainage properties, and achieving even shredding of all material types, preventing clogging and maintaining functional reliability.
Implementation Method 1
the cutting chambers are oriented and designed in such a way that the raw material you pick up is fed back to the central area of the perforated work surface and thus back into the main cutting process
Implementation Method 2
Raw materials are comminuted in knife-perforated disc systems according to the principle of deep-drawing deformation of the material into the holes and subsequent separating cut with the knife
Implementation Method 3
The cutting chambers, which take up solid raw material portions of the material to be shredded, which accumulate in front of the knives during the cutting process, also represent an additional cutting system, whereby the circulating knives remove partial amounts of material due to the feed flow thrust and cut them through at the upper edge of the cutting chambers
Data Source
Figure 1~3
AI summary
The set has a perforated disk (2) with multiple boreholes (6), which form working surfaces. Two sets of cutting chambers (3) are provided in an afflux-side area of the working surfaces such that the chambers are provided in external and central areas of the working surfaces. The closed chambers are oriented and designed such that a raw material in cooperation with an associated cutting blade (1) is returned towards a middle area of the working surfaces and is returned to a main cutting process. Thee raw material is received from the clambers.