Two-Stage Cyclone Material Removal for Continuous Micro Trenching
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Solution Overview
Problem
Existing micro trenching operations face inefficiencies due to the need to periodically remove vacuum trucks or trailers for excavated material disposal, leading to reduced productivity and increased costs, as current systems have limited capacity and require multiple units, which are expensive and often necessitate specialized licenses.
Innovation Solution
A material removal system comprising a collection conduit, primary and secondary particle separator systems, and a conveyor system that allows continuous removal of particulate material, including a two-stage separation process using cyclone separators with different cut-points, and a flexible collection conduit for efficient excavation material handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If vacuum trucks or trailers are used to collect excavated material, then the material can be removed from the job site, but the limited tank capacity requires periodic removal and emptying, reducing productivity
Solution Approach 1:
The system divides the particle separation function into multiple stages with different cyclone separators, each handling specific particle size ranges. This segmentation allows continuous processing without capacity limitations, as each stage operates independently and simultaneously.
Solution Approach 2:
The system performs preliminary particle separation at the excavation site using the multi-stage cyclone system, preventing fine particles from being transported away. This preliminary action eliminates the need for periodic trips to disposal sites, maintaining continuous operation.
2Productivity
If multiple vacuum trucks or trailers are provided to maintain continuous operation, then productivity is maintained, but equipment costs and operational expenses significantly increase
Solution Approach 1:
The system combines multiple particle separation functions into a single integrated multi-stage cyclone system. By merging the separation capabilities that would otherwise require multiple vacuum vehicles into one unified system, it achieves continuous operation with a single unit, reducing equipment costs and complexity.
Solution Approach 2:
The multi-stage cyclone system performs multiple functions simultaneously: separating different particle size ranges, collecting various types of excavated material, and preparing materials for different disposal or reuse destinations. This multi-functionality replaces what would otherwise require multiple specialized vehicles.
3Productivity
If multiple vacuum trucks or trailers are used, then continuous material removal is achieved, but specialized licenses and heavy-duty vehicles are required, increasing operational costs
Solution Approach 1:
The system replaces the mechanical vacuum suction system with a cyclone separation system that uses centrifugal force generated by rotating airflow. This substitution eliminates the need for high-power vacuum pumps and heavy-duty vehicles, allowing operation with lighter, easier-to-license equipment while maintaining continuous operation capability.
4Quantity of substance
If excavated material is hauled away to a different location, then the job site is cleared, but time and resources are consumed for transportation and dumping
Solution Approach 1:
The system extracts fine particles from the excavated material stream at the source using the cyclone separation system. By removing problematic fine particles immediately at the excavation site rather than transporting all material away, it eliminates unnecessary transportation time and allows selective disposal of only the separated fine material.
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
Enables continuous removal of excavated material without pausing the operation, reduces equipment costs, and eliminates the need for specialized licenses by using lighter-duty vehicles, enhancing operational efficiency and reducing costs.
Implementation Method 1
A pump or blower assembly 22 operatively connected to secondary particle separator system 16 creates a pressure difference to induce a flow of air
Implementation Method 2
A primary particle separator system operatively connected to a proximal end of the collection conduit separates quantities of particulate material entrained in an air stream
Implementation Method 3
a two-stage separation process using cyclone separators with different cut-points
Data Source
AI summary
A material removal system includes a collection conduit having a distal end that is positionable adjacent particulate material. A primary particle separator system connected to the collection conduit separates quantities of particulate material entrained in an air stream. A secondary particle separator system connected to an outlet of the primary particle separator system separates additional quantities of particulate material entrained in an air stream exiting the primary particle separator system. An air pump connected to an outlet of the secondary particle separator system creates an airflow through the collection conduit and the primary and secondary particle separator systems. A conveyor system operatively associated with material discharge ports of the primary and secondary particle separator systems collects separated particulate material from the material discharge ports of the primary and secondary particle separator systems and transports the separated particulate material to a material discharge end of the conveyor system.