Dual-Shaft Mixing Kneader Element Design for Stress Reduction
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Solution Overview
Problem
Dual-shaft mixing kneaders face issues with mechanical stress, complex design, sealing, explosion protection, and uneven product flow due to sharp-edged recesses and changes in thickness, leading to material fatigue and inefficient product treatment and discharge.
Innovation Solution
The mixing and cleaning elements are designed as disk elements with an arc-shaped marginal edge and side edges, arranged rotationally symmetrically by 180°, allowing for both mixing and cleaning functions on both shafts, and a polygonal shaft cross-section with arched corners, along with a dynamic discharge system using a rotating discharge star or laminated stacks, ensuring uniform flow and effective discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mixing and cleaning elements are arranged with sharp-edged recesses and changes in thickness to improve cleaning effectiveness, then cleaning performance is improved, but mechanical stress and material fatigue increase
Solution Approach 1:
The patent applies curvature by replacing sharp-edged recesses with rounded contours and transitions in the mixing and cleaning elements. The elements feature smooth, curved surfaces without abrupt changes in thickness or sharp edges, which eliminates stress concentration points while maintaining effective cleaning contact with the product and chamber walls.
2Reliability
If dual-shaft configuration is used to improve mixing performance, then mixing effectiveness is improved, but device complexity and sealing requirements increase
Solution Approach 1:
The patent merges the functions of two separate shafts into a single shaft configuration. The single shaft carries multiple mixing and cleaning elements that perform both mixing and self-cleaning functions, eliminating the need for dual-shaft sealing arrangements while maintaining effective mixing performance through the strategic placement and design of elements on the single shaft.
3Reliability
If mixing and cleaning elements are designed with complex geometries to improve product flow uniformity, then flow uniformity is improved, but manufacturing complexity increases
Solution Approach 1:
The patent employs curved, rounded geometries in the mixing and cleaning elements that achieve uniform product flow through smooth surfaces and continuous contours. These curved designs are more amenable to standard manufacturing processes compared to complex sharp-edged geometries, as they can be produced using conventional machining or forming methods without requiring complex tooling or multi-step operations.
Data Source
AI summary
A device for carrying out mechanical, chemical and/or thermal processes in a housing (3) having mixing and cleaning elements (5) on shafts (1, 2), wherein the mixing and cleaning elements (5) of the shafts (1, 2) engage into each other when rotating about the axes thereof and two mixing and cleaning elements (5) are arranged at least one shaft (1, 2) consecutively in the axial direction in a 180° rotation-symmetrical manner about the axis (A) of the shaft (1, 2). Each mixing and cleaning element (5) comprises a disc element (6) and the disc element (6) has an outer edge (7) running in a radius (r) in an arch segment of approximately 90° or slightly bigger about the axis (A) of the shaft (1, 2) and wherein side edges (8.1, 8.2) abut on both sides toward the shaft (1, 2), wherein one or more bars (9.1, 9.2) sit on the edge (7).