Composite Vibratory Screen Structure for Corrosion and Fatigue
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Solution Overview
Problem
Conventional vibratory screens suffer from corrosion, fatigue, and frequent refurbishment due to impact strikes and corrosive environments, especially in liquid separation processes, leading to high maintenance and operational costs.
Innovation Solution
The implementation of a protective cover for support beams composed of polyurethane with deflecting elements and a carbon fibre-reinforced structure, including inner and outer carbon fibre layers with a foam core, to deflect material away from the beams and enhance resistance to corrosion and fatigue.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional steel and stainless steel components are used in vibratory screens, then initial manufacturing cost is reduced, but corrosion and fatigue resistance deteriorate leading to frequent refurbishment
Solution Approach 1:
The support beam is constructed as a composite structure combining a steel I-beam with a polyurethane protective layer. The steel provides structural strength while the polyurethane layer provides corrosion and fatigue resistance, creating a composite material system that overcomes the limitations of conventional steel components in corrosive environments.
Solution Approach 2:
A polyurethane protective layer (flexible shell) is applied over the steel I-beam support structure. This thin film protects the underlying steel from corrosion and fatigue damage while allowing the steel to maintain its structural function, effectively isolating the metal from harmful environmental factors.
2Strength
If steel support beams are used without protection, then structural strength is maintained, but impact resistance from ore particles deteriorates
Solution Approach 1:
The polyurethane protective layer acts as a flexible shell that absorbs impact forces from ore particles while protecting the steel I-beam from direct contact with corrosive materials. This shell protects against both mechanical impact and chemical corrosion simultaneously.
Solution Approach 2:
The polyurethane layer serves as an intermediary between the steel support beam and the harsh operating environment (ore particles and corrosive liquids). It mediates the interaction by absorbing impact forces and preventing direct contact between the steel and corrosive substances.
3Productivity
If frequent refurbishment is performed, then operational continuity is maintained, but loss of time and capital increase
Solution Approach 1:
The polyurethane protective layer is applied in advance to prevent corrosion and fatigue damage before they occur. This preliminary protective action eliminates the need for frequent refurbishment operations, allowing continuous operation without interruption for maintenance.
Data Source
AI summary
The invention provides a vibratory screen (100) with several improvements. A side panel (160) comprises an outer carbon fibre layer (1720), an inner carbon fibre layer (1710) and a foam layer (130) between the inner and outer carbon fibre layers. A support beam (140) comprises an inner core (1420) having at least one carbon fibre layer and an outer polymeric shell (1425) formed on the at least one carbon fibre layer. A protective cover (1800) for the support beam (140) comprises a cover body (1810) and one or more deflecting elements (1820) for deflecting material away from the support beam. Other improvements include a protective plate (200) for the side panels (160) and a driver member assembly (130) having drive beams (400) with an opening (480) to relieve stress.