Mesh Screen Separator for Reusable Abrasive Recovery
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Solution Overview
Problem
Blast machines often fail to effectively separate reusable abrasive media from non-reusable media, leading to significant waste of valuable abrasive materials, which are then discarded and sent to landfills, resulting in substantial financial losses for users.
Innovation Solution
An apparatus comprising a mesh screen, vibratory motor, hoses, adapters, and a flow monitor is used to separate reusable abrasive media from non-reusable media by routing the reusable media back into the blast machine or collection container and the non-reusable media to a discard barrel, with the vibratory motor enhancing separation efficiency and the flow monitor providing cost-saving estimates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional blast machine separators are used, then separation of reusable abrasive media from non-reusable media is performed, but the separators are not kept in peak operating condition causing tons of good abrasive to travel with discards into waste barrels
Solution Approach 1:
The patent introduces an intermediate screening apparatus with a mesh screen as a mediator between the blast machine separator and the discard barrel. This intermediary device catches reusable abrasive media that would otherwise contaminate the discard stream, allowing for separate collection and return of reusable media to the blast machine.
Solution Approach 2:
The invention extracts the reusable abrasive media from the mixed discard stream by routing it through a mesh screen that separates good abrasive from fines and dust. The reusable media is taken out and routed back to the blast machine, while only the non-reusable fines are sent to the discard barrel.
2Productivity
If integrated separators in blast machines are used, then reusable media is routed back into the blast machine, but the separators cause good abrasive to be sent to landfills due to improper operation
Solution Approach 1:
The mesh screen acts as an intermediary that intercepts reusable abrasive media before it reaches the discard barrel. This intermediate screening step ensures that even when the integrated separator operates suboptimally, reusable media can still be recovered and returned to the blast machine through the intermediary apparatus.
Solution Approach 2:
The system implements a dual-path approach where reusable abrasive media is recovered through the mesh screen and routed back to the blast machine, while only the non-reusable fines are discarded to the barrel. This recovery mechanism prevents loss of valuable abrasive material to landfill.
3Loss of substance
If a mesh screen apparatus is added to separate good abrasive from dust and fines, then reusable abrasive is saved from waste barrels, but the device complexity increases
Solution Approach 1:
The separation system is segmented into two independent stages: the integrated separator in the blast machine and the intermediate mesh screen apparatus. This segmentation allows each component to perform a specific function - the integrated separator handles initial separation while the mesh screen provides secondary screening, making the overall system more manageable and maintainable despite increased complexity.
Solution Approach 2:
The mesh screen apparatus serves as a simple intermediary device that adds minimal complexity to the system. By using a straightforward mesh screen design rather than a complex automated system, the invention achieves effective separation while keeping the added device complexity relatively low.
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 apparatus efficiently separates reusable abrasive media from non-reusable media, reducing waste and saving users tens of thousands of dollars in abrasive costs by effectively routing reusable materials back into the system and discarding non-reusable materials, thereby optimizing abrasive media management.
Implementation Method 1
vibratory motor enhancing separation efficiency
Data Source
AI summary
A shot peening efficiency system for separating reusable abrasive media from non-reusable media includes a housing having an opening configured to receive an abrasive media inlet valve; and a separator assembly disposed within the housing, the separator assembly comprising at least one mesh screen and at least one vibratory motor. The housing includes a main channel having a first channel for reusable abrasive media and a second channel for non-reusable abrasive media. The separator assembly is configured to separate reusable abrasive media from non-reusable abrasive media by passing the reusable abrasive media via the first channel and by passing the non-reusable abrasive media via the second channel. The first channel terminates at a reusable abrasive media outlet valve connected to at least one first abrasive media hopper; the second channel terminates at an abrasive media discard outlet valve connected to at least one second abrasive media hopper.