Molten Metal Circulation Drive Device Using Partition Plate
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Solution Overview
Problem
Existing methods for metal melt circulation and agitation, such as inert gas blowing and mechanical pumping, face issues like pipe clogging, high maintenance, large equipment size, and heat generation in stainless steel reinforcement, while magnet-type agitators suffer from leakage and high maintenance costs.
Innovation Solution
A compact metal melt circulating drive device with a hermetically-sealed drive chamber and a permanent magnet unit positioned above the melt tank, using a partition plate to manage flow channels and prevent leakage, allowing for efficient and safe agitation without direct contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a mechanical pump is used to circulate and agitate melt, then the circulation and agitation of melt can be achieved, but large running cost is required
Solution Approach 1:
The patent replaces the mechanical pump system with a magnetic field-based agitation system. Permanent magnets are arranged in a rotating pattern around the melt container, creating a time-varying magnetic field that induces eddy currents in the conductive melt. These eddy currents generate electromagnetic forces that directly drive the melt circulation and agitation, eliminating the need for mechanical pumps and significantly reducing running costs.
Solution Approach 2:
The patent changes the operating parameters by using a rotating magnetic field with specific frequency and intensity. The permanent magnets are rotated at controlled speeds to create alternating magnetic flux that optimizes eddy current generation. By adjusting the rotation speed and magnetic field strength, the system achieves effective melt agitation with minimal energy consumption compared to mechanical pumping.
2Productivity
If a magnet type agitator with permanent magnets is used, then melt can be driven by magnetic lines of force, but the size of the device is increased and the cost of equipment is large
Solution Approach 1:
The patent divides the magnetic agitation system into segmented permanent magnets arranged in discrete positions around the melt container. Instead of using a single large magnet or continuous magnetic structure, multiple smaller permanent magnets are distributed circumferentially. This segmentation allows for compact arrangement, easier installation, and reduced overall device size while maintaining effective magnetic field coverage for melt agitation.
3Productivity
If a magnet type agitator is used, then melt can be driven magnetically, but melt may leak and a high level of maintenance is required
Solution Approach 1:
The patent eliminates mechanical contact between the agitation system and the melt by using a purely magnetic field-based approach. The permanent magnets rotate externally around the melt container without penetrating or contacting the melt. This non-contact magnetic coupling drives melt circulation while completely preventing leakage risks associated with mechanical seals, shafts, or impellers that would require maintenance.
Solution Approach 2:
The magnetic field acts as an intermediary between the rotating permanent magnets and the melt. Instead of direct mechanical or physical contact, the magnetic field transmits energy and momentum to the conductive melt, inducing eddy currents that drive circulation. This intermediary mechanism ensures complete isolation between the drive system and the melt, preventing leakage and eliminating maintenance requirements.
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 solution provides a cost-effective, compact, and low-maintenance system that effectively circulates and agitates metal melts without leakage, reducing energy loss and maintenance time, while ensuring safety and efficient melt circulation.
Implementation Method 1
a magnet type agitator that includes permanent magnets where magnetic lines of force are horizontally emitted and enter and which are placed next to the melt present in a container and drives the melt by rotating the permanent magnets while the magnetic lines of force emitted from the permanent magnets pass through the melt
Implementation Method 2
drives the melt by rotating the permanent magnets while the magnetic lines of force emitted from the permanent magnets pass through the melt
Data Source
Figure 1~2
Figure 3~4
Figure 5(a)~5(b)
AI summary
There is provided a melt circulating drive device that is compact and obtains a large drive force. A melt circulating drive device is mounted on a side wall of a main bath and is driven to agitate nonferrous metal melt present in a melt storage room storing nonferrous metal melt of the main bath. The melt circulating drive device includes a melt drive tank, a melt drive unit, and a partition plate. The melt drive tank includes a hermetically-sealed drive chamber, the drive chamber includes an opening allowing the drive chamber to communicate with the melt storage room, and the melt drive tank stores melt, which flows from the opening, in the drive chamber. The melt drive unit is installed above the melt drive tank. The melt drive unit includes a permanent magnet unit that is rotated about a first up and down axis while making magnetic lines of force up and down pass through the melt present in the drive chamber of the melt drive tank, and a drive unit for the permanent magnet unit that rotates the melt, which is present in the drive chamber, about the first up and down axis by rotationally driving the permanent magnet unit. The partition plate is disposed upright in the drive chamber of the melt drive tank along a direction where the drive chamber and the melt storage room communicate with each other. An outer end of the partition plate is positioned in a region of the opening. An inner end thereof is positioned in the drive chamber. A melt rotating gap is formed between the inner end and an inner surface of the drive chamber facing the inner end. The partition plate divides the opening of the drive chamber into a first opening and a second opening positioned on both right and left sides of the partition plate. The partition plate is rotated by the melt drive unit, and discharges melt, which collides with one surface of the partition plate, from the first opening so as to allow external melt to be sucked into the drive chamber, in which the pressure of the melt has been reduced, from the second opening.