Compressed Air Supply Device for Bulk Material Dust Separation
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Solution Overview
Problem
Compressed air conveyor systems for bulk materials face challenges with dust content, which affects processing, clogs filters, and poses explosion risks, as existing solutions only clean the transport air and not the granules, leading to frequent manual cleaning and spatial constraints.
Innovation Solution
A granulate separator with a dust separator design where the dust is collected separately from the granules, using a coarse sieve to allow dust to pass into a dedicated dust collection container with a large filter, allowing for extended unmanned operation and efficient dust removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a filter is arranged in the ceiling area of the separator to clean transport air, then the transport air is cleaned, but the filter clogs frequently requiring manual cleaning and the dust falls back into granules
Solution Approach 1:
The invention separates the dust collection function from the granulate collection function by providing a dedicated dust collection container (12) with its own filter (2), while the granulate separator (1) maintains its own collection area (4). This segmentation prevents dust from contaminating the granulate and allows the dust filter to be optimized independently without affecting granulate handling operations.
Solution Approach 2:
The dust collection function is extracted from the main granulate separator structure and placed in a separate dust collection container (12) positioned at a distance from the granulate separator. This extraction allows the dust filter to be cleaned or replaced without interrupting granulate collection operations and prevents dust from falling back into the granulate.
2Productivity
If a coarse sieve is used to separate granulates from transport air, then granulates are effectively separated, but dust accumulates on the sieve requiring regular cleaning
Solution Approach 1:
The invention introduces a dedicated dust collection container (12) with its own filter (2) as an intermediary to capture dust particles that pass through the coarse sieve (5). This intermediary dust collection system prevents dust from accumulating on the sieve, maintaining separation efficiency without requiring frequent sieve cleaning.
3Area of stationary object
If the dust collection container is placed close to the granulate separator, then the system is compact, but dust can fall back into the granule collection area
Solution Approach 1:
The dust collection container (12) is extracted from the immediate vicinity of the granulate separator (1) and positioned at a distance where dust falling from the filter (2) cannot contaminate the granulate collection area (4). This spatial extraction eliminates the risk of dust return while still maintaining system compactness through strategic positioning.
4Area of stationary object
If a small filter is used in the separator ceiling, then the system is compact, but the filter clogs quickly reducing unmanned operation time
Solution Approach 1:
The filtering function is segmented into two independent systems: a small filter (5) in the granulate separator for granulate collection and a large filter (2) in the separate dust collection container (12) for dust filtration. The dust filter can be designed with larger dimensions to handle dust loads without clogging, extending unmanned operation time without compromising system compactness.
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 effectively separates dust from granules, reduces filter clogging, and allows for longer unmanned operation by using a large filter surface, minimizing dust return to the granule collection area and enabling efficient dust collection without interfering with granule delivery.
Implementation Method 1
only the granulate grains, all of which cannot penetrate this sieve, are due to gravity in the Deposit the granule collection area below the screen in the granule separator
Implementation Method 2
a filter through which the dust can no longer penetrate, so that the dust is deposited on the filter
Implementation Method 3
By blowing compressed air, usually with more than 1 bar overpressure, into this suction lance, a suction effect is created in the suction lance in the conveying direction, which sucks in the granules
Implementation Method 4
the transported goods, e.g. B. granules or ground material falls down in the separator and is usually fed to a consumer arranged underneath, for example a granulate dryer or directly to a plastic injection molding machine, due to the force of gravity
Data Source
Figure 1a
Figure 1b
Figure 2a
AI summary
The separator (1) has a filter (2), which is penetrated by feed air (3) arranged aside a granulate collecting area of the separator and in a dust collecting tank (12). A screen (5) penetrated by the feed air and the separator is not penetrated by material such as granulates, to be conveyed. A feed pipe (15) is opened out in the separator for delivering the material to be conveyed. A compressed air outlet is opened out in a feed pipe upstream of the separator. The dust collecting tank is a separate container connected with the separator over a dust pipe (20). Independent claims are also included for the following: (1) a compressed air supply device for granulates and mill material, comprising a compressed air source (2) a method for separating fractions of different grain size e.g. dust, and larger particles in material to be conveyed.