Magnetic Coupling Agitator With Split Bearings for Higher Mixing Loads

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Solution Overview

Problem

Conventional agitators with mechanical seals face issues such as leaks, high maintenance costs, and contamination risks in the pharmaceutical and food industries, while magnetic coupling agitators are limited by rotary bearings that restrict torque, speed, and agitator blade size, leading to increased vibrations and mechanical damage.

Innovation Solution

The agitator design incorporates a split bearing arrangement with two rotary bearings, one closer to the magnetic coupling and the other further away, allowing for increased load-bearing capacity, stability, and service life, enabling higher drive power, longer agitator shafts, and greater mixing efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a single rotary bearing is used in the magnetic coupling agitator, then the structure is simple, but the load-bearing capacity is limited and vibrations increase

Engineering Contradiction:

Improvebearing structureVSAvoidload-bearing capacity

Core Design Contradiction:

Device complexityVSStrength

Solution Approach 1:

The single rotary bearing is divided into two separate rotary bearings arranged in series along the agitator shaft. This segmentation allows each bearing to share the load, increasing the overall load-bearing capacity while reducing vibrations through distributed support. The first bearing is positioned closer to the magnetic coupling and the second bearing further away, creating a more stable structural configuration.

Inventive Principle:

Principle #1Segmentation

2Productivity

If the drive unit power is increased to improve mixing efficiency, then the mixing performance improves, but the single bearing cannot withstand the increased loads

Engineering Contradiction:

Improvemixing efficiencyVSAvoidbearing durability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

By dividing the bearing support into two separate rotary bearings, the system can withstand higher drive powers without compromising reliability. The distributed load configuration allows the agitator to operate at higher speeds and with more powerful drive units while maintaining bearing durability and preventing mechanical damage.

Inventive Principle:

Principle #1Segmentation

3Device complexity

If mechanical seals are used in conventional agitators, then the structure is simple, but leaks and contamination occur

Engineering Contradiction:

Improvesealing structureVSAvoidcontamination risk

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The mechanical seal system is replaced with a magnetic coupling system. The magnetic coupling transmits rotational force from the drive unit to the agitator shaft through magnetic fields without physical contact, eliminating the need for mechanical seals that can leak. This substitution completely prevents contamination risks associated with seal failures while maintaining structural simplicity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Length of moving object

If longer agitator shafts are used to reach larger vessels, then the mixing coverage increases, but the single bearing cannot handle the increased vibrations and loads

Engineering Contradiction:

Improveagitator shaft lengthVSAvoidagitator stability

Core Design Contradiction:

Length of moving objectVSStability of the object's composition

Solution Approach 1:

The bearing support system is segmented into two bearings positioned at different locations along the agitator shaft. This segmentation provides distributed support that stabilizes longer shaft configurations, reducing vibrations and preventing mechanical damage. The first bearing closer to the magnetic coupling and the second bearing further away create multiple support points that enhance overall system stability for extended shaft lengths.

Inventive Principle:

Principle #1Segmentation

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

This design enhances stability and load-bearing capacity, reduces the risk of bearing fractures, allows for larger agitated vessels and more inhomogeneous media processing, and ensures thorough mixing with increased rotation speeds and larger agitator blades.

Implementation Method 1

a magnetic coupling, the magnetic coupling having drive magnets connected to the drive unit and agitator head magnets connected to the agitator head

Methodology Applied

Scientific EffectMagnetic coupling: Magnetism

Data Source

PatentEP3354334B1Mixer for a mixing tank

Publication Date: 2021.06.09 ZETA BIOPHARMA

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AI summary

Agitator (2) for a stirred tank (20), which agitator (2) comprises an agitator head (1), a drive unit (4) and a magnetic coupling (3), the magnetic coupling (3) having drive magnets connected to the drive unit (4). (5) and has agitator head magnets (6) connected to the agitator head (1), the agitator head (1) having agitator blades (7) and a bearing arrangement (8), and the agitator blades (7) with the agitator head magnets (6) and the Bearing assembly (8) are connected, wherein the bearing assembly (8) rotatably supports the agitator head (1), and the bearing assembly (8) comprises a first rotary bearing (9), wherein the bearing assembly (8) comprises a second rotary bearing (10) which is arranged at a distance from the first rotary bearing (9) in the agitator head (1).