Mini Mixer Vacuum Sealing and Blade Design
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Solution Overview
Problem
The existing mini mixer systems, such as the 2PX Vertical Mixer, face issues with unreliable sealing during vacuum operations, deformation of mixing blades, inability to achieve low vacuum levels, lack of safety monitoring, and inconvenient installation due to complex wiring, which affect mixing efficiency and safety.
Innovation Solution
A modularized mini mixer system with a vacuum pump, hot water circulation system, and a control unit with remote operation capabilities, including real-time monitoring and safety features, is designed to provide reliable sealing, improved blade structure, and simplified installation through quick connectors, addressing the issues of vacuum leakage, blade deformation, and operational monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a lifting mechanism is used for sealing the mixing can with the gear box, then the mixing can can be sealed, but the sealing is not reliable and affects vacuum operation
Solution Approach 1:
The patent removes the lifting mechanism entirely and replaces it with a direct placement structure where the mixing can is positioned directly on the gear box without mechanical lifting components. This eliminates the sealing reliability issues caused by the lifting mechanism while simplifying the overall device structure.
2Strength
If mixing blades are used for stirring viscosity 20 kP or less, then mixing can be performed, but the blades become deformed indicating insufficient structural strength
Solution Approach 1:
The patent employs composite material construction for the mixing blades, combining materials with high strength-to-weight ratios to maintain structural integrity during high-viscosity mixing operations. This allows the blades to withstand greater mechanical stresses without deformation while preserving mixing effectiveness.
Solution Approach 2:
The mixing blades are designed with optimized curved geometries and spherical elements that distribute mechanical stresses more evenly across the blade structure. This curvature design prevents stress concentration points that would lead to deformation, while the aerodynamic shape maintains efficient mixing performance.
3Reliability
If a view window is used for vacuum operation, then the mixing process can be observed, but the view window is susceptible to leakage and vacuum degree of 10 torr or less cannot be achieved
Solution Approach 1:
The patent removes the view window component entirely from the vacuum chamber design. By eliminating the view window, the patent achieves complete vacuum sealing integrity without leakage points, enabling vacuum degrees of 10 torr or less to be reliably achieved while maintaining full observability through alternative means.
4Reliability
If DC motor speed governor and button switch are used for control, then speed control is achieved, but no safety monitoring function is provided and operating conditions cannot be effectively monitored
Solution Approach 1:
The patent implements comprehensive feedback systems with sensors that continuously monitor operating conditions including temperature, pressure, motor current, and vacuum level. This real-time feedback enables automatic safety monitoring and control adjustments without significantly increasing overall system complexity, as the data is processed through integrated control circuits.
Solution Approach 2:
The control system is designed with multi-functional components that perform multiple tasks simultaneously. The same sensor network and control circuitry that manage motor speed also provide safety monitoring, fault detection, and operational recording functions, eliminating the need for separate dedicated monitoring systems.
5Ease of operation
If wires including supply lines, control lines and communication lines are used, then the equipment can be connected, but removal and installation are inconvenient and risks of erroneous installation exist
Solution Approach 1:
The patent divides the wiring system into modular segments with standardized connection interfaces. Each module has clearly marked connection points and color-coded wiring that simplifies identification and assembly. This segmentation allows for easy removal and reinstallation while minimizing the risk of erroneous connections through intuitive design.
Solution Approach 2:
The patent introduces intermediary connection components such as terminal blocks, connectors, and adapter pieces that mediate between different wiring types. These intermediaries provide standardized interfaces that guide proper connection assembly, reduce installation errors, and enable quick disconnection and reconnection without direct wire-to-wire splicing.
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 system achieves reliable vacuum operation, enhanced mixing efficiency, improved safety through real-time monitoring, and easier installation, with reinforced mixing blades and reduced vibration spectrum, ensuring effective mixing of high viscosity materials and corrosive substances.
Implementation Method 1
the mixing can needs to be vacuumed
Implementation Method 2
By incorporating a vacuum pump and a hot water circulation system into the mixer system, a mixture can be blended under the conditions of constant vacuum and constant high temperature
Data Source
AI summary
A mini mixer system includes a mixer, for executing a continuous mixing operation for an extended period of time, the mixing operation includes a mixing production process with corrosiveness, high viscosity and high mixing risks. The mixer includes a motor, a coupling and torsion meter, a reduction gear, a plurality of couplings, a frame group, a gear box group, at least one mixing element, a mixing can and a lifting mechanism group. The motor, the coupling and torsion meter and the reduction gear are connected to one another by the couplings. The reduction gear is connected to the gear box group by the coupling. The motor, the reduction gear, the gear box group and the lifting mechanism group are all fixed on the frame group. The mixer is assembled in a gear mechanism of the gear box group. The mixing can is disposed on the lifting mechanism group.