Magnetic Separator Conveyor with Reverse Air Flow

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Solution Overview

Problem

High intensity magnetic separator conveyors face contamination issues due to the presence of non-magnetic plastic debris and fibrous materials coated with ferrous dust, which are not effectively removed in preliminary low magnetic intensity separation steps, leading to unwanted co-separation with stainless steel items and contamination of the output.

Innovation Solution

Integration of a reverse air flow generating apparatus within the magnetic separator conveyor that uses a laminar air flow to winnow ferrous dust coated non-ferrous debris from the magnetic attachment on the conveyor belt, allowing it to separate from stainless steel items and fall into a different collection bin, preventing contamination.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If high intensity magnetic separation is used to separate stainless steel parts, then magnetic separation effectiveness is improved, but non-magnetic plastic debris coated with ferrous dust is co-separated causing output contamination

Engineering Contradiction:

Improvemagnetic separation effectivenessVSAvoidoutput contamination

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The separation process is divided into two distinct phases: first, magnetic separation to remove ferrous and magnetically susceptible materials; second, air winnowing to remove ferrous dust coated non-magnetic debris. This segmentation allows each process to target specific contaminants without affecting the other, resolving the contradiction between separation effectiveness and output purity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A stream of air is introduced as an intermediary substance between the magnetic separation process and the stainless steel output. The air stream selectively removes ferrous dust coated non-magnetic debris from the conveyor belt surface, acting as a mediator that eliminates contamination without interfering with the magnetic separation of stainless steel parts

Inventive Principle:

Principle #24Intermediary (Mediator)

2Quantity of substance

If preliminary low magnetic intensity separation is used to remove paramagnetic ferrous parts, then initial magnetic separation is achieved, but ferrous dust coated non-ferrous debris remains in the mixture

Engineering Contradiction:

Improveremoval of paramagnetic ferrous partsVSAvoidcompleteness of separation

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The low intensity magnetic separation is performed as a preliminary action to remove the bulk of ferrous and magnetically susceptible materials. This preliminary step reduces the load on the subsequent high intensity magnetic separation and air winnowing processes, while the air winnowing completes the separation by removing the remaining ferrous dust coated non-magnetic debris

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces reliance solely on magnetic mechanical separation with a combination of magnetic separation and pneumatic action. The air stream substitutes for magnetic force in removing non-magnetic materials coated with ferrous dust, complementing the mechanical magnetic separation system to achieve more complete separation

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Effectively prevents contamination of stainless steel output by ensuring ferrous dust coated non-ferrous debris is separated and collected separately, improving the purity of the stainless steel output by utilizing a reverse air flow to distinguish and redirect the debris during the high intensity magnetic separation process.

Implementation Method 1

a high intensity magnetic roller... capable of forwardly winnowing the ferrous dust coated non-ferrous debris at the point of magnetic release of the stainless steel parts and pieces

Methodology Applied

Scientific EffectMagnetic field: Magnetic Field

Implementation Method 2

an air knife configured plenum component fixedly mounted and operatively positioned beneath the lower flight of the continuously circulating conveyor belt and adapted to emit a longitudinal stream of air in the forward conveyor direction at or immediately below the continuously oppositely longitudinally moving juncture of the lower end of the longitudinal roller and the longitudinal end of the belt's lower flight

Methodology Applied

Scientific EffectLaminar flow: Laminar Flow

Data Source

PatentUS10252275B2Magnetic separator conveyor

Publication Date: 2019.04.09 BUNTING MAGNETICS CO INC

AI summary

A magnetic separator incorporating a rigid frame having left and right rails having longitudinal and oppositely longitudinal ends; longitudinal and oppositely longitudinal rollers respectively mounted at the left and right rails' longitudinal and oppositely longitudinal ends, the longitudinal roller having an interior cylindrical space; a multiplicity of magnets within the interior cylindrical space; a continuous loop belt mounted over the longitudinal and oppositely longitudinal rollers, the belt having a longitudinally movable upper flight, a longitudinal end, and a simultaneously oppositely longitudinally movable lower flight having a longitudinal end; a plenum mounted beneath the lower flight, the plenum having an air input port and having an air output port, the plenum's air output port being positioned for directing a flow of air toward the lower flight's longitudinal end; and an air impeller operatively mounted in communication with the plenum's air input port.