Horizontal Mixer Stacked Augers Mixing Efficiency
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Solution Overview
Problem
Conventional horizontal mixers for bulk agricultural materials require significant horsepower and time to mix large loads, resulting in inefficient power usage and prolonged mixing times.
Innovation Solution
A horizontal mixer design featuring a stacked auger setup with at least one ribbon auger at the bottom and one or more top augers, utilizing a W-shaped trough for bottom augers and dual pitch configurations to enhance mixing efficiency and quality, allowing for faster mixing and reduced power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional single auger mixers are used, then the structure is simple, but the mixing time is long (8-10 minutes) and power consumption is high
Solution Approach 1:
The mixer is divided into multiple independent augers (typically 3-5 augers) arranged in parallel, each capable of rotating independently. This segmentation allows each auger to handle a portion of the mixing task, significantly reducing overall mixing time from 8-10 minutes to 2-3 minutes while distributing the power load across multiple units.
Solution Approach 2:
The invention transitions from a single horizontal auger to multiple augers arranged in a three-dimensional configuration within the mixing chamber. This spatial arrangement increases the effective mixing volume and improves material circulation patterns, achieving faster mixing without simply increasing the size of a single auger.
2Use of energy by moving object
If conventional single auger mixers are used, then the device is simple, but power consumption is high due to large load
Solution Approach 1:
The total power requirement is distributed across multiple independent augers, each driven by its own motor or shared power source. This segmentation reduces the power burden on each individual auger and allows for more efficient power utilization across the system, decreasing overall power consumption despite the added complexity of multiple units.
Solution Approach 2:
Multiple augers create overlapping mixing zones and redundant material circulation paths, ensuring that material is continuously moved and mixed from multiple directions simultaneously. This partial redundancy in the mixing action improves efficiency and reduces total energy consumption by preventing dead zones and improving material flow dynamics.
3Loss of time
If conventional mixers are used, then the structure is simple, but mixing time is prolonged (8-10 minutes)
Solution Approach 1:
Multiple augers work simultaneously in parallel, each contributing to the mixing process. This segmentation of the mixing function across multiple units reduces the time required to achieve thorough mixing from 8-10 minutes to 2-3 minutes, as material is circulated and mixed by multiple independent actions occurring concurrently.
Solution Approach 2:
The multiple augers create continuous material circulation throughout the mixing chamber, eliminating dead zones and ensuring constant movement of material. This continuous action from multiple sources simultaneously maintains vigorous mixing throughout the entire load, significantly reducing the time to achieve uniform mixing.
4Productivity
If stacked auger configuration is implemented, then mixing efficiency improves, but device complexity increases
Solution Approach 1:
The invention arranges multiple augers in a three-dimensional stacked configuration within the mixing chamber, utilizing vertical and horizontal space efficiently. This multi-dimensional arrangement increases mixing efficiency by engaging material from multiple levels and angles simultaneously, achieving superior mixing performance without requiring a proportionally larger mixer volume.
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 significantly reduces mixing time to as low as 2 minutes and decreases power requirements by approximately 40% while maintaining or improving mix quality, enabling faster and more energy-efficient mixing of bulk agricultural materials.
Implementation Method 1
a pitch on the one or more bottom ribbon augers is adapted to draw material inwards from the front and rear wall towards a middle area of the container
Implementation Method 2
a pitch on the one or more top augers is adapted to draw material outwards from a middle area of the container towards the front and/or rear walls
Data Source
AI summary
A horizontal mixer for mixing bulk material, such as agricultural material, is provided. The horizontal mixer includes a mixing container for accommodating bulk agricultural material to be mixed. The mixing container includes side walls connected at their bottom edges by a trough; a front wall spanning a front side of the container; a rear wall spanning a rear side of the container; and an exit door through which mixed agricultural material can exit. Further, one or more bottom augers situated longitudinally in the trough, wherein at least one of the one or more bottom augers is a ribbon auger; and one or more top augers situated longitudinally in the mixing container stacked above the one or more bottom ribbon augers. The trough has a shape to accommodate the one or more bottom ribbon augers.