Powder-Filling System With Non-Uniform Sieve for Density Uniformity
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Solution Overview
Problem
The air-tapping method for filling containers with powder results in non-uniform filling density due to varying cohesive forces among powder particles, leading to higher density near the hopper's side wall and lower density at the center, causing uneven product properties.
Innovation Solution
A powder-filling system with a sieve member having smaller openings near the side wall than at the center, which impedes the fall of powder particles near the side wall, ensuring uniform filling density across the container by using a pulsed gas supply to facilitate even powder distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a uniform sieve member with equal opening sizes is used, then the device structure is simple, but the filling density becomes non-uniform (higher near side wall, lower at center)
Solution Approach 1:
The sieve member is designed with non-uniform opening sizes where the opening size varies depending on the radial position from the hopper center. Specifically, openings are smaller near the side wall region and larger near the center region, creating local quality variations that compensate for the non-uniform cohesive forces and fluidity of powder particles at different locations.
2Productivity
If compressed gas is supplied continuously, then powder fills quickly, but the filling density becomes non-uniform due to varying cohesive forces
Solution Approach 1:
Compressed gas is supplied in a pulsed manner rather than continuously. The gas supply is interrupted periodically, creating cycles of gas pressure application and release. This periodic action allows powder particles to settle and distribute more uniformly during the gas release phases while still maintaining overall filling speed during the pressurized phases.
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 system achieves approximately uniform filling density within the container, enhancing the consistency of the filled product's properties, particularly relevant for sintered magnet production where uniform magnetic properties are critical.
Implementation Method 1
compressed gas is rapidly charged through a gas introduction port into the space above the powder within the hopper, and after a short period of time, the compressed gas is discharged from the hopper. Such a charge and discharge of the compressed gas is alternately repeated at a frequency of several tens of times per second
Implementation Method 2
a sieve member provided at the opening, the sieve member having smaller openings in a region near a side wall of the hopper than in a central region of the hopper
Data Source
AI summary
A powder-filling system capable of filling a container with powder at an approximately uniform filling density has: a hopper having an opening removably and hermetically closably attached to the container, the hopper communicating with the container at the opening for supplying powder to a container; a powder supplier for supplying powder to the hopper; a gas supplier for repeatedly supplying compressed gas in a pulsed form to the hopper, with the hopper hermetically closably attached to the container; and a sieve member provided at the opening and having a smaller openings in a region near a side wall of the hopper than in its central region. The smaller openings in the region near the side wall of the hopper where the powder more easily falls from the hopper into the container impedes the fall of the powder in that region and improves the overall uniformity in the filling density.