Downdraft Winnower with Ballistic Plate for Cacao Chaff Separation
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Solution Overview
Problem
Conventional winnowing systems for cacao are inefficient, cumbersome, and prone to clogging, requiring large spaces and high maintenance, with batch processing speeds being slow and inefficient due to reliance on freefall or carefully calibrated drift tubes.
Innovation Solution
A downdraft winnower system that uses a diverter wall to transition the mixture flow from vertical to horizontal, where it collides with a ballistic plate, and fluidically accelerated mixture to separate chaff from food material, with a circulating design for finer separation and easy cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional drift tunnel winnowing systems are used, then separation of chaff from food material is achieved, but the systems require large volume drift tunnels and large amounts of time and labor to collect and utilize effectively
Solution Approach 1:
The patent transitions from horizontal drift tunnel geometry to a vertical winnowing chamber configuration. Material is introduced at the top and moves downward through the chamber, utilizing the vertical dimension for separation. This dimensional change achieves effective separation while dramatically reducing the horizontal space requirements compared to conventional drift tunnels.
2Productivity
If grated winnowers with multiple layers of vibrating grates are used, then higher yields and separation efficiencies are achieved, but the layered design makes them difficult to clean due to tight working spaces and large surface area
Solution Approach 1:
The patent eliminates the complex layered grate structure entirely, extracting only the essential winnowing function. By using a simple vertical chamber with air current separation, the design achieves adequate separation efficiency while making the entire interior accessible and easy to clean, removing the cleaning difficulties inherent in multi-layered grate systems.
3Manufacturing precision
If conventional batch processing winnowing systems are used, then separation is achieved, but the processing speeds are slow and inefficient due to reliance on freefall or carefully calibrated drift tubes
Solution Approach 1:
The patent implements continuous material flow through the vertical winnowing chamber, eliminating the batch-by-batch processing of conventional systems. Material is continuously introduced at the top and processed as it moves downward, maintaining continuous separation action throughout the chamber, which dramatically increases processing speed while maintaining separation quality.
4Manufacturing precision
If large volume drift tunnels are used for sufficient separation, then commercially acceptable grades are achieved, but large amounts of time and labor are required to collect and utilize effectively
Solution Approach 1:
By switching from horizontal to vertical configuration, the patent enables more compact separation chamber design that reduces both the physical space required and the time needed for material to traverse the separation zone. The vertical arrangement allows gravity to assist the downward flow, reducing traversal time while maintaining effective separation.
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 high-volumetric processing rates with efficient separation and easy maintenance, overcoming the limitations of existing systems by achieving high separation ratios and flexibility in handling variable feed stocks.
Implementation Method 1
A downdraft winnower receives a mixture of chaff and food material and fluidically accelerates the mixture downward into a winnowing chamber
Implementation Method 2
Winnowing typically is the process of separating grain, seed, or other food materials from their chaff or shells by blowing a current of air through an unseparated mixture. The lower-density chaff and/or shells travel a greater distance in the air current than the higher-density food product resulting in a separation gradient.
Implementation Method 3
A diverter wall transitions the accelerated mixture flow from vertical to horizontal, where it abruptly collides with a ballistic plate member
Implementation Method 4
A ballistic plate member abruptly collides with the accelerated mixture, thereby releasing a substantial portion of any residual chaff that may remain bonded to food material and/or otherwise fracturing desired food products
Implementation Method 5
heavier density food products fall through to a selector chute below the winnowing chamber, while lighter density chaff is carried upward by the air current to a chaff chute
Data Source
AI summary
Methods, systems, and apparatus for winnowing. In one aspect, a method includes loading an initial material into a winnowing system via a feed member; feeding the material into a fluidically accelerated winnowing cavity, where the initial material impacts at least one plate member to yield chaff material and processed material, and where the processed material and the chaff material circulate in the winnowing cavity; and separating the chaff material and the processed from the winnowing cavity based on density. Other aspects include yielding intermediate material, where the intermediate material reimpacts the at least one plate member until yielding chaff material and processed material, preprocessing the initial material, controlling the flow of initial material into the winnowing cavity with a feed gate, where the chaff material egresses the winnowing cavity via a chaff chute, where the chaff material collects in a collection cavity, and/or more.