Keel Ram Apex Design for Reducing Mixer Rotor Forces
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Solution Overview
Problem
In internal batch mixers with counter-rotating, non-intermeshing rotors, the traditional 'V' shape ram design experiences significant cyclical rotational forces, leading to increased noise, wear, and mechanical damage due to aggressive material flow and higher rotor speeds, which compromises mixing efficiency and machine durability.
Innovation Solution
A ram design with a protruding apex on its central portion and horizontal or less protruding end portions, reducing the rotational forces on the ram, thereby minimizing noise and wear while maintaining effective distributive and dispersive mixing characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional 'V' shape ram design is used in internal batch mixers with counter-rotating, non-intermeshing rotors, then distributive and dispersive mixing is achieved, but significant cyclical rotational forces cause increased noise, wear, and mechanical damage
Solution Approach 1:
The ram bottom surface is segmented into three distinct regions: a central protruding apex section and two lateral non-protruding sections. This segmentation allows different portions of the ram to perform different functions - the central apex reduces cyclical rotational forces and noise, while the lateral sections maintain mixing effectiveness. The segmentation resolves the contradiction by localizing the noise-reducing feature to where it is most needed without compromising overall mixing performance.
Solution Approach 2:
The ram design applies local quality by creating a protruding apex only in the central portion of the bottom surface, while the lateral portions remain flat or non-protruding. This local modification specifically targets the area experiencing the most cyclical rotational forces and noise generation, reducing harmful effects at the source without altering the entire ram structure, thus maintaining mixing effectiveness while reducing noise and wear.
2Productivity
If rotor speeds are increased to decrease mixing cycle times, then productivity improves, but cyclical rotational forces on the ram increase significantly
Solution Approach 1:
The protruding apex on the ram is designed in advance to counteract the cyclical rotational forces generated by high-speed rotor operation. By incorporating this anti-action feature into the ram structure before operation begins, the design prevents the harmful effects of increased forces rather than reacting to them during operation, allowing high rotor speeds to be used without excessive wear or damage.
3Ease of manufacture
If a flat bottom ram design is used, then manufacturing is simpler, but material stagnates under the flat section and does not enter the mixing chamber effectively
Solution Approach 1:
The ram design incorporates a dynamic protruding apex that moves with the ram during operation, actively engaging with the material to prevent stagnation and promote mixing chamber entry. This dynamic feature maintains manufacturing simplicity while significantly improving material flow and mixing efficiency, resolving the contradiction between ease of manufacture and productivity.
Data Source
AI summary
This invention provides a ram for use in a mixer with counter-rotating non-intermeshing rotors on which the central portion of the ram utilizes a apex, either a point or a line produced by a “V” or similar shape, that protrudes a given distance into the mixing chamber and on which the end portions of the ram are either horizontal such that they do not protrude into the mixing chamber at all or are otherwise shaped such that they protrude into the mixing chamber less than the apex of the central portion of the ram.