Offset Batcher Gate for Asphalt Silo Segregation
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Solution Overview
Problem
Asphalt batcher gates in existing technologies are prone to segregation due to horizontal motion, leading to separation of materials of differing weights and densities, and are difficult to maintain and service, often resulting in operational failures and material segregation.
Innovation Solution
The design features a batcher gate assembly with offset doors that guide materials towards the center, paired with an actuator assembly for easy operation and maintenance, allowing for the batcher gate to be readily inserted, removed, and serviced without removing the batcher from the silo, using a combination of gate assemblies and actuation systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single trap door gate opens from one side, then the gate structure is simple, but material segregation occurs due to horizontal motion
Solution Approach 1:
The gate is divided into two separate gates hinged on opposite walls of the batcher, each opening outward from the center. This segmentation allows material to be discharged symmetrically from both sides simultaneously, canceling out horizontal motion effects and preventing segregation while maintaining structural simplicity
Solution Approach 2:
The patent employs symmetric asymmetry by having two gates hinged on opposite walls that open in opposite directions. This creates a balanced asymmetric configuration where the horizontal forces generated by each gate cancel each other out, preventing material segregation while maintaining ease of operation
2Reliability
If the gate is fixed to the batcher, then the gate provides stable discharge control, but maintenance and servicing are difficult
Solution Approach 1:
The gate assembly is designed as a removable unit that can be extracted from the batcher for maintenance and servicing. The gate includes fastening mechanisms that allow it to be securely attached during operation but easily removed when maintenance is needed, enabling technicians to service the gate without dismantling the entire batcher structure
Solution Approach 2:
The gate transitions from a static fixed structure to a dynamic removable assembly. The gate can be inserted, secured, and removed as needed, providing both stable discharge control during operation and easy access for maintenance. This dynamic design allows the gate to adapt between operational and maintenance states
3Stability of the object's composition
If material drops from the center into the batcher, then the material stays mixed, but the gate must open from center which complicates the mechanism
Solution Approach 1:
The center-opening mechanism is achieved through segmentation into two gates hinged on opposite walls. Each gate opens outward from the center position, and when both gates open simultaneously, they create a combined center discharge effect that maintains material mixing while using simple hinged mechanisms rather than a complex central opening 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 configuration ensures even distribution of materials, reduces segregation, and facilitates easy maintenance, minimizing downtime for service or repair, thereby maintaining the integrity of the asphalt mix and extending the operational life of the asphalt plant.
Implementation Method 1
a batcher gate assembly pivotal about a horizontal axis and rotatable between a closed position in which the batcher gate assembly blocks the batcher outlet opening and an open position in which the batcher gate assembly permits materials to pass from the batcher receptacle body
Data Source
AI summary
An asphalt batcher has top and bottom coupling flanges that bolt to a silo, conveyor, and related apparatus. The batcher includes a receptacle for selectively receiving and retaining materials. The receptacle has a material splitter to divide material flowing into the batcher into at least two separate funnels. Adjacent to the outlet, each of the funnels have a receptacle side wall opening. At least one pair of removable batcher gate assemblies are readily inserted into and removed from the receptacle side wall openings. Each batcher gate assembly has a batcher gate door. The pair of batcher gate doors are placed offset from center, closer to the opposed outer walls, and open toward each other and therefore the center to guide materials from the batcher receptacle body out of the batcher and into the silo center. Receptacle side wall access doors provide inspection of and access to the two funnels.