Composite Workpiece Air Filtration With Multi-Cyclone Chip Extinguishing
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Solution Overview
Problem
Existing machining systems for composite material workpieces containing metal and non-metal produce vapors, smoke, and fumes, which are harmful and energetically inefficient to exhaust directly, and existing air cleaning systems are not flexible, space-efficient, or cost-effective.
Innovation Solution
A multi-stage air cleaning system comprising a cyclone separation stage with multiple cyclones, a mechanical filter stage, and two activated carbon filter stages, arranged in a specific configuration to enhance cleaning performance, reduce noise, and optimize space usage, with flexible operation across varying air flow rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single cyclone is used for chip separation, then the device structure is simple, but the chip extinguishing reliability is insufficient
Solution Approach 1:
The single cyclone is divided into multiple parallel cyclones (at least three, preferably at least six) to increase the total surface area for chip extinguishing. This segmentation allows each cyclone to handle a portion of the air flow while collectively providing enhanced extinguishing capability, resolving the contradiction between reliability and structural simplicity.
2Reliability
If activated carbon filter stages are placed upstream of the blower, then cleaning performance is improved, but noise level increases
Solution Approach 1:
The single filter stage is segmented into two separate activated carbon filter stages positioned on opposite sides of the blower. This segmentation allows the system to maintain high cleaning performance while reducing noise, as the blower is isolated between two identical filter stages rather than having all filters upstream.
Solution Approach 2:
The blower acts as an intermediary element positioned between two activated carbon filter stages. This arrangement allows the blower to be shielded from direct exposure to unfiltered contaminated air on both sides, reducing noise transmission while maintaining effective air cleaning performance.
3Area of stationary object
If a compact filter arrangement is used, then space requirements are reduced, but maintenance accessibility is worsened
Solution Approach 1:
The filter system is segmented into two independent activated carbon filter stages that can be accessed and maintained separately. This segmentation allows for compact overall arrangement while maintaining ease of maintenance, as each filter stage can be serviced independently without requiring complete disassembly of the entire system.
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 system provides reliable chip extinguishing, high cleaning performance, reduced noise, compact design, and cost-effective operation with extended maintenance intervals, ensuring safe and efficient air purification.
Implementation Method 1
a cyclone separation stage, having upwardly directed outlets for the purified air
Implementation Method 2
the cyclone separation stage has a package of at least three, preferably at least six, individual cyclones connected in parallel fluidically to one another
Implementation Method 3
a mechanical filter stage and two activated carbon filter stages
Implementation Method 4
the upper dividing plate has an opening for a filter group arranged fluidically between the middle zone and the upper zone, comprising the mechanical filter stage and a first activated carbon filter stage
Implementation Method 5
comprising the mechanical filter stage and a first activated carbon filter stage
Implementation Method 6
The fan is preferably designed as a radial fan with a fan wheel arranged in the fan chamber and driven by a motor to rotate about a horizontal axis
Data Source
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AI summary
A device for machining composite workpieces comprises a machining center and an extraction and cleaning device (3) for air containing chips separated from the machining center. The extraction and cleaning device (3) comprises a blower (12), a cyclone separator stage (8), a mechanical filter stage (9), and two activated carbon filter stages (10, 11). A first section of the extraction and cleaning device (3) comprises three zones (17, 18, 19) arranged one above the other, separated from each other by partitions (20, 21). The cyclone separator stage (8) is integrated into a lower partition (20), and an upper partition (21) has an opening for a filter group (30) comprising the mechanical filter stage (9) and a first activated carbon filter stage (10). The upper zone (19) communicates with the intake opening (41) of the blower (12) via a calming zone (36).A partition (43) separates a blower chamber (40) from an outlet chamber (44) arranged next to it, which houses the blower motor (15) and which is supplied with pre-cleaned air from the blower chamber (40) via a second activated carbon filter stage (11).