Dust Removal System With Adjustable Atomizing Balls
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Solution Overview
Problem
Current dust removal systems in the metal processing industry face issues with high viscosity and agglomeration of dust, leading to blockages and corrosion, resulting in short device life and reduced efficiency.
Innovation Solution
A two-stage atomization system with coordinating atomizing balls and umbrella-shaped atomizers, along with a regulating mechanism to adjust clearances and flare angles, ensures effective atomization and contact between water and dust, addressing blockages and corrosion while improving the atomizing effect.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bag-type dust removal device is used, then dust gas can be filtered, but high viscosity dust with agglomeration tendency blocks micro-holes causing short working life
Solution Approach 1:
The patent uses water spray system to create water mist that captures dust particles in the gas stream. Water is introduced through nozzles and atomized to form fine droplets that collide with and capture dust particles, then the water-dust mixture is removed. This hydraulic approach replaces the bag filtration method that clogs with high-viscosity dust.
2Reliability
If fan-leaf-type dust removal device is used, then water mist can be formed to remove dust, but corrosive dust adheres to and corrodes the fan body reducing atomization effect
Solution Approach 1:
The patent extracts the atomization function from the rotating fan body and transfers it to a stationary nozzle system. The fan body is completely removed, and water atomization is achieved through high-velocity spray nozzles that generate fine water mist without any rotating components that could be corroded or accumulate dust.
Solution Approach 2:
The mechanical rotating fan system is replaced with a stationary pneumatic-hydraulic spray system. Instead of using mechanical rotation to atomize water, the patent uses high-velocity gas flow through nozzles to atomize water, eliminating the mechanical components susceptible to corrosion and dust accumulation.
3Reliability
If dense-spout-type dust removal device is used, then water mist can be generated to capture dust, but burrs accumulate on spout surfaces blocking them and reducing working life
Solution Approach 1:
The patent removes the dense spout structure entirely and replaces it with a nozzle system that introduces water directly into the high-velocity gas stream. The atomization occurs in the free stream rather than through confined spout openings, eliminating the surfaces where burrs could accumulate and block flow.
Solution Approach 2:
The patent transitions from a confined spout-based atomization approach to a free-stream injection approach. Water is injected into the three-dimensional gas flow field where atomization occurs through turbulent mixing and shear forces, rather than being constrained to two-dimensional spout openings that are prone to blockage.
4Reliability
If conventional dust removal equipment is used, then dust can be removed, but frequent clearing of burrs increases labor intensity and reduces efficiency
Solution Approach 1:
The patent designs a system where water is continuously introduced and flows through the atomization zone, naturally carrying away dust particles and preventing accumulation on surfaces. The flowing water serves both the atomization function and the self-cleaning function, eliminating the need for manual clearing operations.
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 system provides stable and continuous dust collection with extended device life by dynamically adjusting clearances and flare angles to maintain effective atomization and contact, reducing labor intensity and improving efficiency.
Implementation Method 1
the atomizing mechanism includes a water chamber, a first and second atomizing ball, an umbrella-shaped atomizer and a regulating mechanism; the first and second water inlets are set oppositely, and the center line of the water inlets is perpendicular to the center line of the water outlets
Implementation Method 2
water flows in the atomizing chamber 21 from the upper opening and hits the rotary fan body 23 to form water mist
Implementation Method 3
the dust gas flows in the atomizing chamber 21 from the lower opening and mixes with the water mist to remove the dust in the dust gas
Implementation Method 4
the water mist mixes with the dust gas to remove the dust in the dust gas
Implementation Method 5
The dust in the dust gas comprises mostly different compounds... high viscosity with high probability to adhere to metal surfaces
Implementation Method 6
water flows in from the inlet of the water chamber 24 and sprays out from the dense small spouts 25 to form water mist
Data Source
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AI summary
This invention relates to a dust removal system for dust gas which comprises at least an atomizer. The atomizer comprises an atomizing chamber and an atomizing mechanism; the atomizing chamber includes an inlet for the dust gas and an outlet for the gas after mixture; the atomizing mechanism comprises a water chamber, the first atomizing ball, the second atomizing ball, an umbrella-shaped atomizer, and a regulating mechanism; the water chamber includes the first and second water inlet and the first and second water outlet; the regulating mechanism adjusts the fit clearance between the first atomizing ball and the first water outlet, the fit clearance between the second atomizing ball and the second water outlet, and the flare angle of the umbrella surface of the umbrella-shaped atomizer. The preferred advantageous effect is: the two-stage atomization - coordinating the atomizing balls and the water outlets, and using an umbrella-shaped atomizer - guarantees the atomizing effect. When there are burrs accumulating in the water outlets, regulate the fit clearances between the atomizing balls and the water outlets to remove completely the influence of the blockage on the atomizing effect. And when there are burrs corroding the water outlets, regulate the fit clearances between the atomizing balls and the water outlets to remove completely the influence of the corrosion on the atomizing effect.