Rotor-Stator Mixer Energy Dissipation Estimation
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Solution Overview
Problem
Current rotor-stator mixers lack a comprehensive performance estimation method applicable to various configurations, leading to inefficient design and production of food, pharmaceutical, and chemical products, as existing methods focus on individual configurations and do not account for processing time effectively.
Innovation Solution
The total energy dissipation rate (εa) is calculated from geometrical sizes, running powers, and flow rates to estimate mixer performance, allowing for the design of high-performance mixers that can handle different configurations and processing times, thereby improving particle size breakup and emulsification effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a comprehensive performance estimation method is developed that accounts for various configurations and processing times, then mixer design accuracy and product quality estimation improve, but the complexity of the estimation method and calculation requirements increase
Solution Approach 1:
The patent transforms the complex performance estimation problem into a parameter-based calculation system. By defining the total energy dissipation rate εa through specific parameters (rotor/stator geometry, rotational speed, fluid properties), the invention provides a systematic approach to estimate mixer performance across different configurations without requiring complex simulations or empirical data for each case.
Solution Approach 2:
The invention creates a universal performance estimation method that can be applied to various mixer configurations (different gap sizes, stator hole patterns, rotor blade designs) and processing conditions (different residence times, flow rates). The single formula εa = P/(ρ·N²·D²) serves multiple purposes: design optimization, performance comparison, and product quality prediction across different application scenarios.
2Adaptability or versatility
If existing performance estimation methods focusing on individual configurations are used, then calculation simplicity is maintained, but adaptability to different mixer configurations and processing times is reduced
Solution Approach 1:
The patent introduces dynamic elements to the performance estimation by incorporating rotational speed (N), residence time (t), and flow rate (Q) as variable parameters. This allows the estimation method to adapt to different operating conditions and processing times, enabling prediction of particle size breakup and emulsification effects at various stages of the processing cycle rather than being limited to a single fixed configuration.
3Manufacturing precision
If high-performance mixers are designed with optimized geometrical sizes and running powers, then particle size breakup and emulsification effects improve, but the complexity of design and manufacturing increases
Solution Approach 1:
The patent provides clear design guidelines based on parameter optimization. By establishing relationships between the total energy dissipation rate εa, rotor/stator dimensions (D), rotational speed (N), and power input (P), the invention enables systematic design of high-performance mixers. The formulas provide direct calculations for optimal geometrical sizes and running powers, simplifying the design process while achieving superior particle size breakup and emulsification effects.
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 approach enables the design and manufacturing of high-performance mixers that achieve better particle size breakup and emulsification effects, both theoretically and experimentally, and allows for the estimation of resulting drop diameters during processing time, enhancing product quality and efficiency in food and pharmaceutical production.
Implementation Method 1
a high shear stress may be produced in the neighborhood of the gap between the stator 3 capable of rotating at high-speeds and the stator 2 being fixed in position
Implementation Method 2
the energy dissipation rate of the turbulent flow will contribute to the particle size breakup effect
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A mixer of the rotor-stator type that includes a stator having a plurality of openings and a rotor disposed on the inner side of the stator and spaced by a predetermined gap away from the stator is described, wherein the mixer that is capable of improving the shearing stress applied upon the liquid being processed and provides the higher performance is proposed, more specifically, the mixer that allows the shearing stress applied upon the liquid being processed to be changed and adjusted accordingly or allows the flow rate in which the liquid being processed flows to be changed and adjusted accordingly is proposed. The stator includes a plurality of stators each having a different circumferential diameter, and the rotor is disposed on the inner side of the plurality of stators and spaced by the predetermined gap away from the stators so that the stators and the rotor can be brought closer to or farther away from each other in the direction in which the rotary shaft of the rotor extends