Floating Follower Plate for Viscous Material Deaeration
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Solution Overview
Problem
Existing apparatuses for conveying viscous materials face challenges in automating the introduction and removal of follower plates, requiring manual skill to manage air inclusions and material waste, especially with expensive materials, and are inefficient in handling air-liquid separation during the process.
Innovation Solution
An apparatus with a follower plate mounted to float vertically, using a de-aeration mode to remove air and an aeration mode to lift the plate, combined with a sensor system for precise positioning, ensures automated and efficient handling of air and material transfer, minimizing material waste and ensuring seamless container transitions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual introduction and removal of follower plate is performed, then air inclusions can be managed with operator skill, but the process requires great skill and is not automated
Solution Approach 1:
The follower plate is designed to float on the viscous material and automatically follow the material level. The plate self-adjusts its position vertically within limits relative to the holding rod, eliminating the need for manual positioning skill while maintaining automated operation.
Solution Approach 2:
The follower plate transitions from a fixed rigid connection to a dynamic floating mounting that allows vertical movement within limits. This dynamic adjustment enables the plate to adapt to changing material levels and air inclusion conditions automatically during the conveying process.
2Loss of substance
If follower plate is rigidly connected to holding rod, then positioning is simple, but air inclusions cannot be effectively removed and material waste increases
Solution Approach 1:
The connection between the follower plate and holding rod is segmented into a rigid holding rod and a flexible floating mounting system. This segmentation allows the plate to move independently vertically while maintaining its horizontal positioning, enabling air removal without increasing overall system complexity.
Solution Approach 2:
The floating mounting acts as an intermediary element between the holding rod and follower plate. It provides the necessary vertical mobility to remove air inclusions while maintaining the structural connection, thus reducing material waste without requiring complex mechanisms.
3Object-generated harmful factors
If follower plate is lowered forcefully onto material surface, then air is removed, but great force is required and manual skill is needed
Solution Approach 1:
The floating mounting system provides a counterbalancing effect that reduces the force required to lower the follower plate onto the material surface. The plate can be gently lowered and will naturally float to the correct position, eliminating the need for great manual force while still removing air inclusions effectively.
Solution Approach 2:
The system utilizes the buoyancy and pressure characteristics of the viscous material itself to assist in positioning the follower plate. The material's hydrostatic pressure helps push the floating plate to the correct level, reducing the external force needed and automating the air removal process.
4Extent of automation
If follower plate follows material level automatically, then automation is improved, but the mounting complexity increases
Solution Approach 1:
The floating mounting system is designed to be self-regulating, using the buoyancy and weight of the follower plate itself to automatically follow the material level. This self-service mechanism achieves automatic positioning without requiring complex sensors, motors, or control systems.
Solution Approach 2:
The patent replaces complex mechanical positioning systems with a simple floating mounting mechanism that uses basic physical principles (buoyancy and gravity). This substitution achieves automatic following of the material level while keeping the mounting complexity low.
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 apparatus achieves automated and precise control of follower plate movements, reducing material waste and air inclusions, enhancing operational efficiency and reducing manual intervention, particularly beneficial for expensive viscous materials.
Implementation Method 1
the floating mounting is arranged between the follower plate and the at least one holding rod so that the follower plate can be moved vertically, within limits, relative to the at least one holding rod, or that it is arranged between the at least one holding rod and a vertically movable support element of the lifting and lowering device that carries the holding rod(s), so that it can be moved vertically, within limits, with reference to the support element, so that the follower plate is drawn further into the container interior by means of the production of a partial vacuum in the container interior
Implementation Method 2
an aeration mode, in which compressed air is introduced into the container interior. The excess pressure in the container interior presses the follower plate upward
Data Source
AI summary
An apparatus for conveying viscous material from a container having a base and an upwardly-extending shell includes: a follower plate movable towards and away from the base adjacent to the shell inner surface facing the interior and having an outlet and at least one deaeration and/or aeration opening; a deaerator for sucking air through the deaeration opening(s) and/or an aerator for introducing compressed air through the aeration opening(s); a lifting/lowering device for lifting/lowering the plate; a control for alternately controlling the lifting/lowering device in a movement mode and the deaerator or aerator in a deaeration or aeration mode, the lifting/lowering device having at least one vertical holding rod connected to a plate upper side, the plate being vertically movable in a limited manner relative to the rod; and a sensor for detecting and transmitting to the control upper and lower end plate positions relative to the rod.