Magnetic Separator Eddy Current Trajectory Optimization
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing magnetic separators for non-ferrous metals are inefficient in separating particles agglomerated with other materials and have limitations in belt speed and maintenance due to restricted interaction zones and potential for mechanical damage from particle intrusion.
Innovation Solution
A magnetic separator design featuring a convex, rounded wall supporting a conveyor belt with a magnetic wheel generating a variable magnetic field, accompanied by a second rotating magnetic wheel with opposite direction, optimizing the separation area and trajectory control, and incorporating a magnetic brake and constant magnetic field for ferromagnetic particle management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the magnetic wheel is arranged as close as possible to the inner surface of the belt guide wheel, then the efficiency of the system is improved, but the risk of seizing or drilling of the guide wheel increases
Solution Approach 1:
The patent introduces a non-conductive intermediary element (such as a non-conductive lining or coating) between the magnetic wheel and the guide wheel. This intermediary maintains the necessary magnetic field strength for efficient separation while preventing direct mechanical contact that would cause seizing or drilling of the guide wheel.
Solution Approach 2:
The patent replaces direct mechanical contact between the magnetic wheel and guide wheel with a magnetic field-based interaction system. The magnetic wheel generates electromagnetic forces for particle separation without requiring physical contact with the guide wheel, thereby eliminating mechanical wear and seizing issues.
2Productivity
If the magnetic wheel rotates at a significantly higher speed, then the separation capability is improved, but the mechanical stress on the system increases
Solution Approach 1:
The patent replaces high-speed mechanical rotation with a magnetic field generation system. The magnetic wheel rotates at moderate speed while generating variable magnetic fields through its rotation, eliminating the need for high-speed mechanical operation and reducing mechanical stress on the system components.
Solution Approach 2:
The patent changes the operational parameter from high rotational speed to controlled magnetic field frequency. By adjusting the magnetic field variation frequency through the rotation speed and magnetic wheel design, the system achieves effective particle separation without requiring excessively high mechanical speeds that would increase stress.
3Productivity
If the interaction zone is extended, then the separation of agglomerated particles is improved, but the device complexity increases
Solution Approach 1:
The patent segments the magnetic wheel into multiple independent magnetic segments or uses a magnetic wheel with multiple poles. This segmentation allows the magnetic field to be applied over an extended interaction zone while maintaining manageable complexity through modular magnetic element arrangement.
Solution Approach 2:
The patent extends the interaction zone by utilizing the vertical dimension in addition to the horizontal conveyor path. The magnetic wheel is positioned to create a three-dimensional magnetic field distribution that interacts with particles over an extended zone, improving separation capability without proportionally increasing horizontal device complexity.
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
Enhances separation efficiency and rate by extending the interaction zone and controlling ejection trajectories, reducing maintenance costs and mechanical issues, while allowing higher belt speeds and improved handling of agglomerated particles.
Implementation Method 1
a particle of non-ferrous metal, that is to say of a paramagnetic material, located close to the magnetic wheel will be subjected to a variable magnetic field. This variable magnetic field will generate electromotive forces which will induce currents in the conductive material of the particles. These currents will create a magnetic field which opposes the magnetic field generated by the magnetic wheel
Implementation Method 2
This variable magnetic field will generate electromotive forces which will induce currents in the conductive material of the particles
Implementation Method 3
These currents will create a magnetic field which opposes the magnetic field generated by the magnetic wheel which is the cause of the variation of the external field. As a result, a repulsive force is applied to the particles which makes them take off from the conveyor belt
Implementation Method 4
Ferrous metal particles or pieces can be separated quite easily by applying a stationary magnetic field near the bulk material, typically by placing a permanent magnet directly above the conveyor belt. Ferrous particles having the particularity of being ferromagnetic or even simply magnetic, they will be attracted by the permanent magnet
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The separator has a magnetic wheel (22) arranged opposite to an inner surface of a round wall (13). The magnetic wheel generates, in rotation, a variable magnetic field in non-ferrous metal particles and/or pieces (16), where the magnetic field induces Foucault current and interaction force with a magnetic field generated by a path that leads to eject the particles and/or pieces from a conveyor belt (2) for separation. The wall encloses one-fourth of circumference of the magnetic wheel at a constant distance. The wall and the magnetic wheel are fixed with a caisson (4).