Automatic Furnace Charging Apparatus with Buffer Bin and Pushing Mechanism
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Solution Overview
Problem
The conventional manual charging of zinc feedstock into a furnace for copper production is labor-intensive and exposes operators to high temperatures, making the process unsafe and inefficient.
Innovation Solution
An automatic charging apparatus for a furnace, comprising a hopper, buffer bin, and a pushing mechanism that allows for precise control of feedstock quantity and speed, with features like preheating using high-temperature gas and tilting arrangements to prevent feedstock from rushing back into the hopper, enhancing safety and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual charging of zinc feedstock is used, then operators can directly control the charging process, but operators are exposed to high temperatures and the process is labor-intensive
Solution Approach 1:
The patent introduces an automatic charging apparatus as an intermediary device between the operator and the high-temperature furnace environment. The apparatus includes a buffer bin positioned away from the furnace, a charging chute with shielding, and automated feeding mechanisms that transfer feedstock without requiring operators to enter or closely approach the high-temperature zone, thus eliminating direct thermal exposure while maintaining operational control
2Device complexity
If manual charging is used, then the process is simple in structure, but the labor intensity is high and efficiency is low
Solution Approach 1:
The charging process is segmented into distinct automated stages: feedstock storage in the buffer bin, controlled discharge through the charging chute, and automated feeding into the furnace. This segmentation allows each stage to be optimized independently with appropriate automation, significantly reducing manual labor intensity while maintaining manageable system complexity through modular design
Solution Approach 2:
The automatic charging apparatus enables the system to serve itself by automating the feedstock transfer process. The buffer bin automatically discharges feedstock, the charging chute automatically controls the flow, and the feeding mechanism automatically delivers material to the furnace, eliminating the need for continuous manual intervention and thereby increasing productivity without proportionally increasing device complexity
3Productivity
If feedstock is charged quickly into the furnace, then production efficiency increases, but feedstock may rush back into the hopper causing control issues
Solution Approach 1:
The buffer bin serves as a preliminary action stage where feedstock is stored and prepared before actual charging. This intermediate buffer allows the system to pre-position material away from the furnace, enabling controlled discharge at optimal timing. The buffer bin acts as a decoupling mechanism that separates feedstock preparation from charging execution, allowing quick charging when needed while preventing rush-back issues through its buffer capacity and controlled discharge mechanism
4Loss of time
If more feedstock is pre-stored in the buffer bin, then charging continuity is improved, but the buffer bin size and device complexity increase
Solution Approach 1:
The buffer bin is designed with dynamic characteristics that allow it to adapt its effective capacity and discharge rate based on operational needs. The bin can be configured to store varying amounts of feedstock depending on production requirements, and its discharge mechanism can adjust the flow rate to match furnace consumption. This dynamic design enables the system to maintain charging continuity with optimized buffer sizes, avoiding excessive volume while ensuring sufficient storage for continuous operation
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 automatic charging apparatus reduces operator labor, ensures accurate and efficient feeding of zinc into the furnace, and preheats the feedstock to reduce melting time, thereby improving production efficiency and safety.
Implementation Method 1
the buffer bin preheats the feedstock
Implementation Method 2
the pushing mechanism comprising a drive and a pushing element, the drive driving the pushing element to perform a reciprocating movement in the buffer channel such that the feedstock in the buffer channel is sequentially pushed into the feeding inlet
Data Source
AI summary
An automatic charging apparatus for a furnace, including: a hopper provided with an inlet and an outlet opening; a buffer bin in which a buffer channel is provided, one end of the buffer channel including a discharge port communicating with the outlet opening, the other end being in communication with a feeding inlet of the furnace; a pushing mechanism configured to push feedstock in the buffer channel sequentially into the feeding inlet of the furnace, the pushing mechanism including a drive and a pushing element, the drive driving the pushing element to perform a reciprocating movement in the buffer channel so the feedstock in the buffer channel is sequentially pushed into the feeding inlet via the reciprocating movement of the pushing element. The solution can implement automatic charging of feedstock in the furnace, reduce labor intensity of operators, and realize accurate control of charging amount of the feedstock.