Disposable Separator Insert with Magnetic Bearing
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Solution Overview
Problem
Current centrifugal separators are cumbersome for laboratory use due to their size and require complex cleaning processes, making them less suitable for applications like biotechnology where hygiene and ease of use are critical.
Innovation Solution
A disposable separator insert with a stationary housing and a rotatable drum, utilizing magnetic bearing devices for non-contact rotation and adjustable speed, allowing for easy separation of flowable suspensions into different phases without the need for extensive cleaning or sterilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional centrifugal separators are used, then separation functionality is achieved, but the device size is large and requires complex cleaning/sterilization processes
Solution Approach 1:
The separator is divided into a permanent housing and a disposable separator insert. The insert contains all product-contacting components (drum, disc pack, inlet/outlet systems) that require cleaning, while the housing remains stationary and reusable. This segmentation allows the complex cleaning task to be simplified by replacing rather than cleaning the insert.
Solution Approach 2:
The separator insert is designed as a disposable component made from inexpensive plastic materials. After use, the entire insert is discarded rather than cleaned and sterilized, eliminating complex cleaning processes. The housing remains and can be reused with a new insert.
2Reliability
If stainless steel construction is used, then durability is improved, but the device requires steam sterilization and is less suitable for laboratory use
Solution Approach 1:
The separator insert is made from disposable plastic components instead of stainless steel. This eliminates the need for steam sterilization (SIP) while maintaining hygiene performance, as the entire insert is replaced after use rather than being sterilized. This makes the device suitable for laboratory and biotechnology applications where ease of sterilization is critical.
Solution Approach 2:
The material of the separator insert is changed from stainless steel to plastic, fundamentally altering the sterilization approach from thermal (steam) to replacement. This parameter change enables the use of disposable components that eliminate complex sterilization processes while maintaining product hygiene.
3Reliability
If a spindle-driven system is used, then mechanical drive is reliable, but the device requires mechanical contact components that complicate disposable design
Solution Approach 1:
The traditional mechanical spindle-driven system is replaced with a magnetic field-driven system. The drum is rotated by magnetic forces generated by a magnetic bearing device, eliminating the need for mechanical contact components like spindles, gears, and bearings within the separator insert. This substitution enables a fully disposable design while maintaining reliable drive functionality.
Solution Approach 2:
A magnetic field is introduced as an intermediary between the stationary housing and the rotating drum. The magnetic bearing device generates a magnetic field that contactslessly transmits rotational force to the drum, eliminating direct mechanical contact. This intermediary approach allows reliable drive transmission without mechanical components in the disposable insert.
4Ease of operation
If the entire drum is made disposable, then cleaning is eliminated, but contactless coupling with the drive is required
Solution Approach 1:
The mechanical coupling between the drive and drum is replaced with a contactless magnetic coupling. The magnetic bearing device generates magnetic fields that transmit rotational force without physical contact, enabling the entire drum to be disposable while maintaining reliable power transmission. This eliminates the need for mechanical interfaces that would complicate the disposable design.
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 solution simplifies the separation process, reduces the need for cleaning and sterilization, and enables the use of disposable components made from plastic or non-magnetic materials, enhancing hygiene and operational efficiency, particularly in biotechnology applications.
Implementation Method 1
at least two rotor units for magnetic bearing devices are arranged at two axially spaced locations of the rotor with the drum, with which the rotor with the drum can be held suspended, rotatably mounted and set in rotation within the housing during operation
Implementation Method 2
a separator insert for a separator which is designed to separate a flowable suspension in a centrifugal field into at least two flowable phases of different density
Data Source
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AI summary
The invention relates to a separator insert for a separator, which is designed for separating a flowable suspension (S) into at least two flowable phases (LP, HP) of different densities in a centrifugal field, and which comprises the following: a housing (1) which is stationary during operation and which is designed in the form of a container that is closed apart from a plurality of openings, wherein these openings are designed at least as follows: as a supply opening (8) for an in-flowing suspension, formed in a first axial boundary wall (6) of the housing (1), and as two openings for the discharge (10, 34) of respective flowable phases of different densities (LP, HP) in an outer casing of the housing (1) and a second axial boundary wall (7) of the housing, or as two openings for the discharge (24, 34) of respective flowable phases of differing densities (LP, HP) in the first and the second axial boundary wall (6, 7) of the housing (1); a rotor arranged within the housing (1) and which can be rotated about an axis of rotation (D) and having a drum (3), which also has openings; and at least two rotor units (4b, 5b) for magnetic bearing units (4, 5) at two axially spaced apart points on the rotor (2) with the drum (3), with which the rotor (2) with the drum (3) can be held in a suspended state, can be rotationally mounted and can be made to rotate within the housing during operation.