Levelling Device for Powder Materials with Segmented Belt
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Solution Overview
Problem
Existing levelling devices for materials in powder or granule form struggle to maintain a homogeneous and constant thickness layer, especially on conveyor planes with irregular surfaces and vibrations, leading to streaks and density differences during the pressing of large ceramic slabs.
Innovation Solution
A levelling device comprising a motorized belt with a leveller system that includes a first element to divert the surface layer upwards and a second element to redistribute it uniformly, ensuring a flat and uniform surface by adjusting the heights and orientations of these elements to counteract irregularities and vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional levelling device is used on a conveyor plane, then the material layer can be spread, but the surface exhibits irregularities, streaks, and density differences due to conveyor vibrations and oscillations
Solution Approach 1:
The levelling device is made mobile relative to the conveyor plane, allowing it to adapt dynamically to vibrations and oscillations. The device can move in the longitudinal direction of the conveyor, transforming from a static to a dynamic system that compensates for conveyor irregularities during operation.
Solution Approach 2:
The levelling device is divided into two separate elements: a first element that raises the surface layer and a second element that redistributes it. This segmentation allows each element to perform its specific function independently, improving overall levelling effectiveness and surface uniformity.
2Productivity
If the conveyor plane advances at varying velocities, then productivity increases, but the material layer thickness becomes non-uniform due to irregular spreading
Solution Approach 1:
The levelling device performs preliminary levelling action on the material layer before it enters the pressing zone. By raising and redistributing the surface layer in advance, the device ensures uniform thickness even when conveyor velocity varies during the pressing operation.
3Device complexity
If a single levelling element is used, then the device complexity is reduced, but the ability to create a completely flat surface is insufficient
Solution Approach 1:
The leveller is segmented into two distinct elements positioned at different heights. The first element (at lower height) raises the surface layer by interfering with it, while the second element (at higher height) redistributes the raised material. This segmentation enables achieving complete surface flatness that a single element cannot provide.
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 achieves a homogeneous and constant thickness layer with a surface free of irregularities, effectively addressing the limitations of prior devices by ensuring uniform distribution and smoothing of the material layer, even under varying conveyor velocities and system oscillations.
Implementation Method 1
a first element (5), arranged at a first height (H1) lower than the thickness (S) of the layer (L), to interfere with a surface layer (L1) of the layer (L), or with an upper layer of the layer (L), and to raise the surface layer (L1) above a height corresponding to the thickness (S)
Implementation Method 2
a second element (6), positioned downstream of the first element (5) with respect to the advancement direction and placed at a second height (H2) greater than or equal to the first height (H1)... to redistribute it uniformly
Data Source
Figure 1
Figure 2
AI summary
Levelling device for materials in powder or granule form, comprising: a rest plane (2), mobile in advancement along a longitudinal direction (X) and predisposed to transport a layer (L) having a thickness (S) of material in powder or granule form. The device comprises a leveller (5,6), positioned above the rest plane (2).