Modular Cyclone Separator Layout for Bottom-Side Maintenance
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Solution Overview
Problem
Existing cyclone separators are cumbersome to maintain due to their design requiring complete removal from piping systems, and they are difficult to retrofit into existing pipe systems without extensive additional piping.
Innovation Solution
A cyclone separator with a modular structure featuring a base body with a recess, an interior cone with a cavity, and a base plate that allows for easy maintenance and replacement of components without removing the cyclone separator from the pipe system. The supply line and derivation are arranged in parallel, and the riser pipe can be easily replaced from below.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cyclone separator is designed with a cover and vertical discharge line arrangement, then the piping system is complete, but maintenance requires complete removal from the pipe system
Solution Approach 1:
The patent inverts the traditional maintenance approach by enabling access to the cyclone separator from the bottom rather than requiring removal from the top. The removable base plate allows technicians to access internal components through the bottom, completely reversing the conventional maintenance paradigm and eliminating the need for complete system disassembly.
Solution Approach 2:
The cyclone separator is segmented into distinct modular components: a removable base plate, an inner cone, and a outer housing. This segmentation allows individual components to be accessed, removed, and replaced independently through the bottom opening, facilitating maintenance without complete system removal while maintaining structural integrity during operation.
2Reliability
If the cyclone separator is retrofitted into an existing piping system, then contamination reduction is achieved, but extensive additional piping work is required
Solution Approach 1:
The cyclone separator is designed with universal bottom mounting capabilities that allow it to be integrated into existing piping systems without requiring extensive custom piping work. The standardized base plate with mounting holes and the ability to connect supply and discharge lines from the bottom make it a universal component that can be retrofitted into various pipe configurations with minimal additional piping.
Solution Approach 2:
The patent transitions from traditional top-down vertical integration to bottom-up integration, changing the dimensional approach of installation. By providing access and connection points at the bottom rather than the top, the device allows for easier integration into existing horizontal piping systems, reducing the need for vertical piping modifications and complex routing.
3Ease of manufacture
If the cyclone separator is designed as a single integrated unit, then manufacturing is simpler, but maintenance requires complete removal and replacement
Solution Approach 1:
The cyclone separator is divided into segmentable components including a removable base plate, an inner cone, and an outer housing that can be manufactured separately and assembled. This segmentation maintains manufacturing simplicity for each individual component while enabling easy maintenance through bottom access, allowing technicians to replace worn components like the inner cone without replacing the entire unit.
Solution Approach 2:
The design introduces dynamic maintainability by making the base plate removable and the inner cone extractable through the bottom opening. This creates a dynamic maintenance system where components can be accessed, inspected, and replaced independently while the rest of the housing remains in place, transitioning from a static monolithic structure to a dynamically maintainable modular system.
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 design simplifies maintenance and component replacement, allows for easier installation and retrofitting into existing pipe systems, and reduces the need for extensive piping, making the cyclone separator more cost-effective and efficient.
Implementation Method 1
a cyclone separator (1) for separating a solids-laden liquid into pure liquid and solids
Implementation Method 2
WO 2005/103447 A1 describes a cyclone separator with a cylindrical body and a cyclone tube which is divided into several ring sections
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to a cyclone separator comprising: a main body (2) having a supply conduit (20), a discharge conduit (21) and a recess (23) which is formed as a blind hole and is open towards a bottom side of the main body (2), the supply conduit (20) opening laterally at a wall region (24) of the recess (23), and the discharge conduit (21) leading from a base area (25) of the recess (23) to a lateral outlet (210) on the main body (2); an inner cone (3) having a cavity (30), the inner cone (3) being located in the recess (23); and a bottom panel (4) which closes the recess (23) on the main body (2), the bottom panel (4) having a soiled media connection (5).