Poker Compactor with Suction Wall for Bulk Material Filling
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Solution Overview
Problem
Existing packaging systems face inefficiencies in filling and deaerating lightweight bulk materials, particularly due to caking issues and complexity in compacting devices, which reduce filling rates and increase energy consumption.
Innovation Solution
A compacting device with a poker compactor featuring a gas-permeable outer suction wall and a vibration generator, which reduces caking by using a rotatably accommodated imbalance device to generate vibrations and enhance degassing through a suction device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a vacuum lance is used to enter the open bag from above during filling, then the filling rate increases, but bulk material builds up caking on the outer vacuum lance surface, considerably reducing efficiency
Solution Approach 1:
The patent applies a vibration generator that generates vibrations in the poker compactor to prevent bulk material from caking on the vacuum lance surface. The vibrations continuously disrupt the formation of compacted layers, maintaining efficient vacuum contact throughout the filling process and preventing the efficiency degradation mentioned in the contradiction.
Solution Approach 2:
The vibration generator is integrated into the poker compactor structure, allowing the system to self-maintain its own performance by generating vibrations that prevent caking. This self-service mechanism ensures continuous efficient operation without external intervention to remove accumulated material.
2Reliability
If a poker vibrator is used to deaerate lightweight bulk materials, then deaeration occurs, but the poker vibrator tends to stir the bulk material around instead of achieving efficient deaeration
Solution Approach 1:
The patent merges the vacuum suction function and vibration generation function into a single integrated poker compactor. The vacuum lance creates suction to remove air, while the vibration generator simultaneously prevents material caking and stirring. This combination achieves efficient deaeration without the unwanted stirring effect of standalone poker vibrators.
Solution Approach 2:
The patent uses pneumatic vacuum suction through the poker compactor to remove air from lightweight bulk materials. The vacuum pressure differential created by the suction device effectively deaerates the material without requiring mechanical stirring, resolving the contradiction between deaeration efficiency and avoiding excessive material movement.
3Reliability
If bottom vibrators are used to compact bulk material, then deaeration is achieved, but compacting takes too long so filling rate efficiency decreases
Solution Approach 1:
The patent uses a vibration generator in the poker compactor to generate vibrations that compact bulk material from the top during filling. This top-down vibration compaction occurs simultaneously with the filling process, eliminating the need for separate bottom vibration compaction steps and significantly reducing total compaction time while maintaining effectiveness.
Solution Approach 2:
The vibration generator begins vibrating the poker compactor before and during the filling process, performing preliminary compaction action as material is added. This preliminary vibration compaction prevents air entrapment from the start, eliminating the need for lengthy post-filling compaction operations.
4Productivity
If a downspout with screw conveyor is used to transport filled material, then filling is achieved, but the batching element requires a relatively large diameter and can only provide rather low filling rates
Solution Approach 1:
The patent extracts the material transport function from a complex screw conveyor system and replaces it with a simple gravity-fed chute. The filled material is conveyed directly from the batching element through a simple outlet into the container, eliminating the need for large-diameter screw conveyors and complex batching mechanisms, thereby increasing filling rate.
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 significantly increases filling efficiency by preventing caking and effectively removing air from the bulk material, improving the suction device's performance and allowing for more efficient compacting of lightweight materials.
Implementation Method 1
a suction device (6) which sucks gas out of the bulk material (3) at the poker compactor (2) through a gas-permeable, outer suction wall (7)
Implementation Method 2
a vibration generator and in particular a rotatably accommodated imbalance device (8) so as to reduce any caking of the bulk material (3) at the suction wall (7) and to support degassing of the bulk material (3) by way of a vibrating motion of the poker compactor (2)
Data Source
AI summary
An apparatus and method for compacting bulk material in an open container having a compacting device including a poker compactor, the poker compactor having an outer wall and being suitable to be inserted into an open container to cause the outer wall of the poker compactor to contact the bulk material and to degas and compact the bulk material in the open container. The outer wall of the poker compactor is at least partially formed by a gas-permeable, outer suction wall of a suction device and the poker compactor includes a vibration exciter to support degassing the bulk material by way of vibrating motion of the poker compactor generated by the vibration exciter. The vibration exciter is radially surrounded by a tube device and the suction wall surrounds the tube device.