Demountable Screen Basket with Segmented Support Rings
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Solution Overview
Problem
Pressure screens in the pulp and paper industry face ring fatigue failure and reduced efficiency due to high dynamic loading, distortion, and material loss in wedge wire baskets, especially in aggressive rotor applications, leading to costly rebuilds and compromised slot accuracy.
Innovation Solution
A demountable screen basket design featuring profiled bars with dovetail portions and sectional support rings that are removably mounted using clamping posts and compressible inserts, allowing for easier assembly and disassembly without welding, reducing material loss and maintaining slot accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If wedge wire baskets are used with aggressive rotors, then high open area and slot accuracy are achieved, but ring fatigue failure occurs due to high dynamic loading
Solution Approach 1:
The support rings are divided into multiple ring sections that can be independently replaced. When fatigue occurs in one section, only that section needs replacement rather than the entire basket, maintaining slot accuracy while addressing reliability issues through modular replacement.
Solution Approach 2:
The invention changes the structural parameter of support rings from solid continuous rings to segmented rings with reduced cross-sectional area in non-critical zones. This reduces stress concentration and fatigue loading while maintaining structural integrity where needed, resolving the contradiction between slot accuracy and fatigue resistance.
2Strength
If wedge wire baskets are welded for assembly, then structural strength is improved, but distortion and stress concentration from welds reduce reliability
Solution Approach 1:
The invention replaces the welding mechanical process with a mechanical fastening system using clamps or bolts to attach profiled bars to support rings. This substitution eliminates thermal distortion and weld-induced stress concentrations while maintaining structural strength through controlled mechanical fastening.
3Ease of repair
If replaceable screening elements are used, then repairability is improved, but manufacturing cost and material loss increase
Solution Approach 1:
The support rings are segmented into multiple sections, allowing replacement of only the damaged portions rather than entire rings or screening elements. This reduces material loss significantly while maintaining ease of repair through modular section replacement.
Solution Approach 2:
The invention enables selective recovery and reuse of undamaged ring sections after basket rebuilds. Healthy sections are retained and reused, while only fatigue-damaged sections are discarded and replaced, minimizing material loss while maintaining repairability.
4Strength
If additional welded or shrink fit rings are added for reinforcement, then strength is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The support rings themselves are designed as segmented structures with strategic reinforcement sections built-in during manufacturing. This integrates reinforcement into the basic ring design without adding separate components, reducing assembly complexity while maintaining strength.
Data Source
Figure 1
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Figure 3A~3C
AI summary
A screen basket with replaceable profiled bars is described herein. The screen basket includes profiled bars evenly spaced circumferentially to form a plurality of continuous slots that covers the whole basket length. The profiled bars are fixed in place by a backing structure, including support rings. The support rings are made of at least two sections.