Disc Filter Segmentation for Lower Part Count and Easier Replacement
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Solution Overview
Problem
Existing disc filters have complex structural designs requiring numerous filter segments and frames, increasing manufacturing costs and complicating module replacement.
Innovation Solution
A simplified disc filter design where filter segments alternate with open spaces, using identical interchangeable filter inserts and intermediate inserts covered by a continuous covering ring, reducing the number of required segments and frames by half.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a modular design with filter frames and filter inserts is used, then manufacturing cost is reduced and replacement is enabled, but structural complexity increases
Solution Approach 1:
The filter disc is divided into modular filter segments that can be independently manufactured and assembled. Each segment contains filter frames with filter inserts, allowing standardized production and easy replacement of individual modules without affecting the entire filter disc structure.
Solution Approach 2:
The filter frames and filter inserts are designed as universal components that can be used across multiple filter segments. The same filter insert design is repeated in different segments, reducing the variety of parts that need to be manufactured and stored, thereby simplifying the overall structural complexity while maintaining manufacturability.
2Area of stationary object
If numerous filter segments with closed filter frames are used, then filtration coverage is improved, but the number of parts increases
Solution Approach 1:
Adjacent filter segments are positioned close together with minimal gaps, and the filter frames of neighboring segments share common supporting structures. This merging of adjacent segments reduces the total number of separate parts while maintaining comprehensive filtration coverage across the entire filter disc area.
Solution Approach 2:
The filter segments are arranged in a radial pattern around the drum, utilizing the radial dimension to maximize filtration coverage. By positioning segments at different radial positions and angles, the design achieves complete circumferential coverage with fewer segments than would be required in a linear arrangement.
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 simplifies construction, reduces parts, and facilitates easy replacement of filter elements, while maintaining effective filtration performance.
Implementation Method 1
disc filter including a centrally positioned drum and at least one filter disc positioned on the drum extending in a filter plane, which includes a plurality of filter segments protruding radially from the drum, each of which has a closed filter frame with two radially protruding frame struts fastened to the drum
Data Source
AI summary
A disc filter including a centrally positioned drum and at least one filter disc positioned on the drum extending in a filter plane, which has a plurality of filter segments protruding radially from the drum, each of which has a closed filter frame with two radially protruding frame struts fastened to the drum, a covering profile that connects the frame struts at the radially outer end, and filter inserts mounted in the filter frame. The filter segments in the filter plane are positioned spaced apart from one another on the drum so that they form an open space between adjacent filter segments and each open space accommodates intermediate filter inserts, which are covered at the radially outer end by covering profiles that span the open space at the radially outer end, and the covering profiles are continuations of one another along a closed circular path, forming a covering ring.