Integral Filter Float for Electromagnetic Pump Molten Metal
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The float frame in electromagnetic pumps used for molten metals tends to crack due to thermal effects, causing the filter to sink and lose buoyancy, resulting in ineffective filtration when damaged.
Innovation Solution
A buoyant float frame with a central aperture and a sealing surface, integrated with a filter, is formed using a molding process from silica-based materials, ensuring the float frame remains buoyant and securely engages the pump inlet even after damage, using a design that includes flanges with chamfers for secure positioning and a filter that adheres to the float frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate float frame and filter assembly is used, then the filter can be positioned on the molten aluminum bath, but the float frame cracks under thermal effects causing the filter to sink and become unretrievable
Solution Approach 1:
The float frame and filter are merged into a single integrated assembly where the filter is disposed within the float frame structure. This integration ensures they move together as one unit, preventing the filter from sinking independently when the float frame is damaged, and simplifies retrieval as a single component.
Solution Approach 2:
The float frame is constructed from composite materials including a floatation material (such as foam or hollow structure) combined with a structurally sound material (such as metal or reinforced polymer). This composite construction provides both buoyancy and thermal resistance, preventing cracking under thermal effects while maintaining durability.
2Weight of moving object
If the float frame is made from traditional materials, then it provides buoyancy, but thermal effects cause cracking and loss of buoyancy over time
Solution Approach 1:
The float frame utilizes composite materials where a floatation material (providing buoyancy through low density) is combined with a thermally resistant structural material (providing strength and crack resistance). This composite structure maintains both light weight for buoyancy and high strength for thermal resistance.
Solution Approach 2:
The float frame design incorporates parameters such as wall thickness, material composition ratios, and structural geometry that are optimized to resist thermal effects. By adjusting these parameters, the float frame maintains buoyancy while withstanding thermal stress without cracking.
3Productivity
If the filter is separately positioned, then it can filter impurities, but when the float frame breaks the filter sinks to the bottom and cannot be easily retrieved
Solution Approach 1:
The filter and float frame are merged into an integrated assembly where the filter is disposed within the float frame structure. This ensures that when the float frame is damaged, the filter remains attached and buoyant, allowing easy retrieval as a single unit while maintaining continuous filtration capability.
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 maintains the buoyancy and sealing engagement of the float frame, ensuring continuous filtration of molten metals by preventing the float frame from sinking, even when damaged, thus ensuring reliable operation and easy retrieval of the filter.
Implementation Method 1
The buoyancy of the float frame holds the float frame against the pump inlet
Implementation Method 2
the liquid metal is subjected to an electromagnetic force in the direction of the flow
Data Source
AI summary
A filtration and float apparatus and method are disclosed, wherein an integrated float frame and filter is provided, a buoyancy of the float frame and filter causing a sealing of the filtration and float apparatus with a pump.