Pressing Unit Roller With Segmented Perforation For Liquid Removal
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Solution Overview
Problem
Existing pressing units for removing liquids from agroalimentary products face challenges in achieving high mechanical strength while maintaining dehydration efficiency, as the welding of perforated metal plates is prone to cracks and failures under mechanical stress.
Innovation Solution
A pressing unit with a roller having a partially hollow lateral surface featuring a first portion with holes for liquid evacuation and a second non-perforated portion for welding the helical element, ensuring high mechanical strength and efficient liquid removal without compromising structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the shaft is covered by a completely perforated bent metal plate to increase filtering surface, then dehydration efficiency is improved, but mechanical strength and reliability deteriorate due to welding cracks
Solution Approach 1:
The metal plate is segmented into multiple zones with different perforation densities. The first zone (near the shaft) has lower perforation density to maintain structural integrity, while the second zone (outer region) has higher perforation density to maximize filtration efficiency. This segmentation allows the plate to simultaneously achieve both mechanical strength and dehydration performance.
Solution Approach 2:
Different regions of the metal plate are given different local qualities in terms of perforation density. The local quality varies from the inner region (lower perforation) to the outer region (higher perforation), optimizing both structural strength where needed and filtration efficiency where appropriate.
2Productivity
If the metal plate is completely perforated to maximize liquid evacuation, then water removal efficiency is improved, but the risk of welding failures increases
Solution Approach 1:
The metal plate is divided into functional zones: a first zone with reduced perforation density near the shaft to minimize welding stress concentration, and a second zone with higher perforation density in the outer regions to maximize liquid evacuation. This segmentation reduces the overall number of weld points while maintaining high water removal efficiency.
Solution Approach 2:
The perforation density parameter is varied across different regions of the metal plate. By changing this parameter from the inner region to the outer region, the design optimizes both structural integrity (fewer holes near the shaft) and filtration performance (more holes at the periphery where stress is lower).
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 achieves high dehydration efficiency with reduced risk of component failure, enhancing operational reliability and cost-effectiveness by allowing maximum water removal while maintaining mechanical strength.
Implementation Method 1
the presses comprise a sort of screw feeder, which comprises a rotating shaft around which an appropriately contoured helical element is wound. The pulp (or other material from which water is to be removed) is thus conveyed toward a forced path
Implementation Method 2
The water can thus be evacuated through the walls of the containment chamber, which is appropriately perforated... allows the outflow of water not only in a centrifugal direction from the external metal plates of the containment chamber
Data Source
Figure 1~2
Figure 3~4
AI summary
A pressing unit for removing liquids contained in material of various types, comprising a chamber (2) for containing at least one screw feeder (3); the screw feeder (3) comprises a roller (4) that rotates about its own longitudinal axis (A) and a helical element (5) that is wound in a spiral around the roller (4); the chamber (2) is affected by an intake port for introducing the material to be pressed and by a discharge port for the pressed material, so as to define a forced pressing path (6) comprised between the chamber (2) and the screw feeder (3); the lateral surface of the roller (4), which is at least partially hollow, comprises a first portion (4a), which has a helical extension around the axis (A) and is provided with a plurality of holes (7), for the evacuation of the liquids removed progressively from the material during its advancement along the path (6), and a second portion (4b), which has a helical extension around the axis (A) and is complementary to the first portion (4a). The helical element (5) is wound around the roller (4) at the second portion (4b), which has a continuous, non-perforated shape.