Synchronous Piston Feeder for Reactor Plug Formation

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Solution Overview

Problem

Existing carbonaceous feeder mechanisms for thermochemical reactors face inefficiencies in plug formation and distribution, leading to potential leaks and energy wastage due to the reliance on single-acting pistons and complex hydraulic systems.

Innovation Solution

A feeder apparatus comprising double-acting and single-acting hydraulic piston cylinder assemblies, which alternately convey compressible material through interconnected cylinders to form and distribute plugs efficiently, ensuring a consistent pressure seal and reducing energy consumption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If single-acting pistons are used in the feeder mechanism, then the hydraulic system can be simpler, but plug formation efficiency decreases and energy consumption increases

Engineering Contradiction:

Improvehydraulic system complexityVSAvoidplug formation efficiency

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The patent applies double-acting pistons that can exert force in both forward and reverse directions, enabling dynamic control of the plug formation process. This allows the system to efficiently push plugs in both directions through alternating piston cycles, improving plug formation speed and efficiency while maintaining system reliability

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The feeder mechanism uses periodic alternating action of multiple piston assemblies, where pistons cycle between forward and reverse strokes in a coordinated sequence. This periodic operation enables continuous plug formation and distribution, enhancing productivity while the modular design keeps complexity manageable

Inventive Principle:

Principle #19Periodic action

2Device complexity

If single-acting pistons are used, then the system structure is simpler, but leaks and energy wastage increase

Engineering Contradiction:

Improvesystem structureVSAvoidplug seal integrity

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

Double-acting pistons provide dynamic bidirectional force application, ensuring that plugs are properly formed and sealed during both forward and reverse cycles. This maintains consistent pressure seals and prevents leaks, improving reliability without requiring overly complex structural designs

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The coordinated operation of multiple piston assemblies ensures continuous useful action with no idle cycles. While one piston is forming or distributing a plug, others are preparing or advancing plugs, maintaining continuous sealing and preventing leaks throughout the operation cycle

Inventive Principle:

Principle #20Continuity of useful action

3Manufacturing precision

If complex hydraulic systems are used, then plug formation can be more precise, but energy consumption increases

Engineering Contradiction:

Improveplug formation precisionVSAvoidenergy consumption

Core Design Contradiction:

Manufacturing precisionVSUse of energy by moving object

Solution Approach 1:

The periodic alternating cycles of double-acting pistons enable precise plug formation through controlled reciprocating motion. Each piston cycle delivers precise formatting pressure and duration, ensuring consistent plug dimensions and quality while the rhythmic operation optimizes energy utilization

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The system divides plug formation into discrete segments handled by individual piston assemblies, each contributing to specific aspects of plug formation. This segmentation allows precise control of each formatting stage while distributing energy consumption across multiple independent units, improving overall efficiency

Inventive Principle:

Principle #1Segmentation

4Reliability

If multiple piston assemblies operate independently, then system redundancy is higher, but coordination complexity increases

Engineering Contradiction:

Improveoperational continuityVSAvoidcoordination system

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The feeder mechanism is segmented into multiple independent piston assemblies that can operate semi-autonomously. Each assembly handles specific plug formation or distribution tasks, providing redundancy while the modular structure simplifies coordination through standardized interfaces and synchronized cycling

Inventive Principle:

Principle #1Segmentation

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 apparatus achieves efficient plug formation and distribution, minimizing leaks and energy usage while maintaining reactor integrity, enabling better mixing of reactants and maintaining operational efficiency even with partial assembly failures.

Implementation Method 1

double-acting and single-acting hydraulic piston cylinder assemblies, which alternately convey compressible material through interconnected cylinders to form and distribute plugs

Methodology Applied

Scientific EffectHydraulic pressure: Hydraulic Press

Data Source

PatentUS10252234B2Synchronous single- and double-acting piston feeder system and method

Publication Date: 2019.04.09 THERMOCHEM RECOVERY INTERNATIONAL INC

AI summary

A mechanism applies necessary forces for the creation of one or more plugs of compressible material to be supplied to a reactor. The plugs are capable of forming a seal between inlets for the plugs and the reactor. The mechanism includes two double-acting hydraulic piston cylinder assemblies coupled with two single-acting hydraulic piston cylinder assemblies.