Piston Pump Lubricant Injection for Thick Matter Filling
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Solution Overview
Problem
Piston pumps for thick materials face challenges in achieving high filling levels in delivery cylinders due to high internal friction, especially with high solids content materials like sewage sludge and concrete, where existing lubrication methods are insufficient.
Innovation Solution
The introduction of a ring nozzle connected to an external pressure line with a high-pressure pump for lubricant injection into the delivery cylinder during suction strokes, combined with a control valve system to manage lubricant distribution and injection, ensuring the lubricant is only injected during suction and not during pressure strokes, significantly increasing the filling level and reducing friction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If continuous lubricant injection is used in the pressure conveying line, then wall friction is reduced and delivery pressure is decreased, but the filling level of the delivery cylinder is not significantly improved and additional lubricant injection intervals are required
Solution Approach 1:
The patent applies preliminary action by injecting lubricant into the delivery cylinder before the suction stroke begins. The lubricant is introduced through the ring nozzle at the mouth area of the delivery cylinder, creating a lubricant layer on the inner wall surface in advance. This preliminary lubrication ensures that when thick matter is sucked in, the wall friction is already reduced, enabling better filling without requiring continuous lubricant injection during the entire conveying process.
Solution Approach 2:
The patent applies local quality by concentrating lubricant injection at the specific location where it is most needed - the mouth area of the delivery cylinder where thick matter enters. The ring nozzle delivers lubricant locally to the inner wall surface at the inlet region, creating a lubricant layer precisely where wall friction between thick matter and pipe wall occurs. This localized approach is more effective than continuous injection along the entire conveying line.
2Stress or pressure
If pre-pressing device is used to increase filling pressure, then filling pressure increases by at least 1 bar, but the filling level improvement is insufficient for high solids content materials
Solution Approach 1:
The patent introduces lubricant as an intermediary substance between the thick matter and the inner wall of the delivery cylinder. This lubricant layer acts as a mediator that reduces wall friction, allowing thick matter to be drawn into the delivery cylinder more effectively. The lubricant enables the suction process to overcome the high internal friction of thick materials without requiring excessive pre-pressing, thereby improving filling level through a different mechanism rather than simply increasing pressure.
3Productivity
If lubricant is injected at high pressure during suction stroke, then filling level increases significantly, but lubricant may be wasted during pressure stroke when not needed
Solution Approach 1:
The patent applies periodic action by controlling lubricant injection to occur only during the suction stroke when the delivery piston moves in the suction direction. The control valve responds to the position and stroke direction of the delivery piston, opening during suction and closing before the pressure stroke begins. This periodic injection timing ensures lubricant is applied when it is needed to reduce wall friction during material intake, and prevents waste by stopping injection when the piston reverses for the pressure stroke.
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 approach enhances the filling level in the delivery cylinder by up to 25% for high-solids materials, with the lubricant layer being carried into the pressure line, reducing the need for additional lubricant injection in the initial sections of the line and maintaining efficient transport pressure.
Implementation Method 1
a ring nozzle (32) which opens into the delivery cylinder (16) and is connected to an external pressure line (34), with the pressure line being able to be pressurized with a lubricant via a high-pressure pump
Implementation Method 2
a control device that responds to the position and/or the stroke direction of the delivery piston (20) in the delivery cylinder (16) and a control valve that is arranged in the pressure line (34) and responds to an output signal of the control device
Data Source
Figure 1
Figure 2a~2b
Figure 3~4
AI summary
The invention relates to a piston pump for thick matter, in particular for high-solids sewage sludge, coal sludge and concrete. The piston pump has at least one delivery cylinder (16) which contains a motor-driven or hydraulically driven delivery piston (20) and which has an orifice (12) which communicates alternately with the interior of a material feed container (10) and with a pressure delivery line (30) in a slide-controlled manner in accordance with the movement of the delivery piston (20). In order to significantly increase the degree of filling of the at least one delivery cylinder (16), an annular nozzle (32) opening into the delivery cylinder (16) in the region of the orifice (12) is provided, and this annular nozzle (32) is connected to an external pressure line (34) to which a lubricant can be admitted.