Powder Mixing Machine with Segmented Cross-Flow Tools
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Solution Overview
Problem
Industrial mixing machines face challenges in achieving thorough mixing in the shortest time while minimizing heat input, which is crucial for preventing the caking of plastic granules and ensuring efficient operation.
Innovation Solution
The method involves generating a low-energy primary mixing material flow to convey material to mixing tools, with a secondary cross-flow responsible for the actual mixing process, allowing for controlled energy input and tool operation, including the use of a conveying tool with a helical segment design for efficient material distribution and a dispersing tool for high-energy mixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-speed mixing tools are used to achieve thorough mixing in shorter time, then mixing productivity is improved, but heat input increases causing material caking
Solution Approach 1:
The mixing process is segmented into two distinct stages: a first mixing stage using a conventional mixing tool at lower speed, and a second mixing stage using a high-speed dispersing tool. This segmentation allows the system to achieve both thorough mixing and high-speed dispersion without excessive heat accumulation, as each stage performs a specific function at appropriate speed levels.
Solution Approach 2:
The mixing head is designed to be pivotably mounted, allowing dynamic adjustment of the mixing container orientation during the mixing process. This dynamic capability enables optimization of material flow and mixing efficiency at different stages, allowing the system to adapt mixing conditions to prevent caking while maintaining productivity.
2Stability of the object's composition
If mixing time is extended to prevent caking, then material quality is improved, but production efficiency decreases
Solution Approach 1:
The mixing process is divided into two sequential stages with distinct functions: first mixing for initial homogenization and second high-speed dispersing for final uniformity. This segmentation achieves superior material composition stability in a reduced total time compared to single-stage mixing, as each stage optimizes specific aspects of mixing efficiency.
Solution Approach 2:
The system changes operational parameters between stages: the first mixing tool operates at lower speed for gentle mixing, while the second dispersing tool operates at high speed for rapid dispersion. This parameter change allows achievement of uniform material composition faster than conventional single-speed mixing by optimizing speed for each mixing phase.
3Manufacturing precision
If high-energy mixing is applied to improve particle dispersion, then mixing quality is improved, but energy consumption increases
Solution Approach 1:
Energy input is segmented into two phases: low-energy first mixing for initial homogenization and high-energy second dispersing for particle dispersion. This segmentation achieves superior particle dispersion with optimized total energy consumption, as the high-energy phase is applied only when necessary for final dispersion quality, rather than continuous high-energy mixing.
Solution Approach 2:
The two mixing stages operate sequentially without interruption, maintaining continuous useful action on the material. The first mixing tool prepares the material for the second dispersing tool, ensuring that the high-energy phase operates on pre-homogenized material, which improves dispersion efficiency and reduces total energy requirements compared to starting with unprepared material.
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 enables gentler mixing with better control, reduces heat input, and allows for optimal mixing of materials by successively feeding them through the mixing tools, preventing caking and enabling efficient cleaning of the mixing machine.
Implementation Method 1
The material to be mixed is thrown upwards in an axial area by the mixing tool or tools, deflected outwards in the radial direction and then, due to the force of gravity, returned to the tools on the inner wall of the container.
Implementation Method 2
The mixing process takes place due to the acceleration of the mixed material at the mixing tool or tools and the turbulence contained in the mixed material flow.
Implementation Method 3
a second motor-driven mixing tool is arranged, engaging radially in the wall section of the container... The at least one mixing tool serves to further input energy into the mixing thrombus generated by the conveying tool and to improve particle dispersion
Data Source
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AI summary
A method for mixing powdered and/or granular substances with a mixing machine 1, comprising a mixing head 3, 24, equipped with one or more elements 12 for connecting it to a container 5 containing a mixture to form a closed mixing vessel containing the mixture, the mixing head 3, 24 being pivotably mounted relative to a frame 2 such that the mixing vessel formed from the mixing head 3, 24 and the container 5 can be pivoted to carry out the mixing process, and comprising a device for generating a mixture stream and at least one rotaryally driven mixing tool W2, W2' engaging in the mixture stream, wherein a low-energy primary mixture stream is generated by means of the mixture stream generation device as a conveying stream for supplying the mixture contained in the mixing vessel to the at least one mixing tool W2, W2', by which mixing tool W2,W2' is a secondary mix stream, comprising only a fraction of the mix material in the mixing container but responsible for the actual mixing process, generated as a cross-flow to the primary mix stream serving as the conveying stream, wherein the primary mix stream is generated by at least one rotating conveying tool W1, W1' arranged in the mixing container. A mixing machine, in particular for carrying out the process, is also described.