Multi-Diameter Disc Screen for MSW Separation Wear Reduction
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Solution Overview
Problem
Disc screens in the materials handling industry face challenges in effectively separating recyclable Municipal Solid Waste (MSW) into fiber materials, plastic containers, and metal containers, with existing designs experiencing wear and requiring frequent replacement, and lacking efficient mechanisms for handling diverse material shapes and sizes.
Innovation Solution
The use of multi-diameter disc assemblies with spacer discs and compound discs of varying diameters and materials, aligned in a stair-step configuration, creates constant InterFacial Openings and secondary slots to separate materials, with the large diameter discs absorbing initial contact and wear, while the spacer discs are made of harder materials to reduce wear and allow for larger shafts, reducing material usage and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If discs are made of softer material to handle diverse material shapes and sizes, then adaptability improves, but wear resistance deteriorates
Solution Approach 1:
The disc assembly is segmented into multiple discs with different materials and diameters. Large diameter discs made of softer, more adaptable material handle diverse material shapes and sizes, while smaller spacer discs made of harder material provide wear resistance and maintain spacing. This segmentation allows each component to specialize in one function.
Solution Approach 2:
Different regions of the disc assembly have different material properties. The large diameter discs use softer material for adaptability, while the spacer discs use harder material for wear resistance. This local differentiation of material quality optimizes both adaptability and reliability in their respective functional zones.
2Ease of manufacture
If uniform discs are used throughout the screen, then manufacturing simplicity improves, but separation efficiency deteriorates
Solution Approach 1:
The screen is divided into multiple disc assemblies with different disc diameters (large, intermediate, small). This segmentation creates variable slot sizes that improve separation efficiency for different material types while maintaining relatively simple manufacturing processes for each disc type.
Solution Approach 2:
Discs of asymmetric diameters are used throughout the screen rather than uniform discs. The large diameter discs create larger openings for bulky items, while smaller discs create tighter slots for smaller materials. This asymmetric configuration optimizes separation efficiency across different material size ranges.
3Ease of manufacture
If smaller shafts are used to reduce costs, then manufacturing costs improve, but disc alignment and spacing stability deteriorate
Solution Approach 1:
The shaft system is segmented into multiple smaller shafts rather than one large shaft. Each shaft supports specific disc assemblies and can be optimized independently. This allows use of appropriately sized shafts that provide sufficient stability without excessive cost.
Solution Approach 2:
Spacer discs serve as intermediary elements that maintain consistent spacing between large diameter discs and the shaft. These spacer discs transfer and distribute forces evenly, ensuring stable disc positioning even with smaller, more cost-effective shafts.
4Reliability
If larger shafts are used to improve disc support and reduce wear, then reliability improves, but material usage and manufacturing costs worsen
Solution Approach 1:
The support function is segmented between multiple smaller shafts and the spacer discs. Rather than relying on one large shaft for all support, the system distributes support functions across multiple components, reducing total material usage while maintaining reliability.
Solution Approach 2:
The spacer discs serve dual functions: maintaining disc spacing and providing structural support to the shaft system. This self-service capability of the spacer discs reduces the burden on the shafts, allowing smaller, more material-efficient shaft designs.
Data Source
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AI summary
A material separation screen includes a number of discs (130), each disc comprising a first and a second section (132A, 132B) wherein each section has a coupling end (143) and an interlocking end (133) where the first interlocking end slidingly interlocks with the second interlocking end and wherein the first and second sections are configured to form multiple arched sides when attached together around a shaft.