Pre-tensioned Sifter Screen with Rigid Extension
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Solution Overview
Problem
Existing sifter screens in vibratory sifters are prone to structural failure and require time-consuming and labor-intensive replacement processes, leading to increased downtime and product loss due to loss of tension and sealing efficiency over time.
Innovation Solution
A pre-tensioned sifter screen with a frame having a plurality of cross-members and a rigid external extension, along with a filtering element securely attached, is designed to resist structural failure and facilitate efficient installation, maintaining tension and sealing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If filter mesh is stretched over a frame that is an integral part of the sifter body, then the filter mesh becomes tensioned and secured in place, but the process involves time-consuming filter mesh changing operations and requires substantial manual labor
Solution Approach 1:
The filter mesh is pre-tensioned on a separate frame assembly before being installed in the sifter. This preliminary tensioning action is performed outside the sifter body, allowing the mesh to be ready for immediate installation without time-consuming on-site tensioning operations.
Solution Approach 2:
The sifting system is divided into separate modular components: a frame assembly with pre-tensioned filter mesh and the sifter body. This segmentation allows the filter mesh to be prepared independently on the frame assembly, then quickly installed as a complete unit in the sifter, reducing downtime and manual labor.
2Ease of operation
If location tabs extend from the base of the frame to create tension across the screen surface, then the screen is secured in place, but the tensioning causes bowing and breaks in the frame body and the location tabs wear out over time
Solution Approach 1:
The tensioning function is extracted from the location tabs and transferred to elastic members (springs) that are specifically designed to provide continuous tension. This separates the structural support function (frame body) from the tensioning function (elastic members), allowing each to be optimized independently without compromising structural integrity.
Solution Approach 2:
The tensioning mechanism transitions from rigid mechanical tabs to elastic members that can dynamically adjust tension parameters. The elastic members maintain optimal tension force while accommodating frame movement and wear, preventing the bowing and breaking that occur with rigid tab systems.
3Ease of manufacture
If the screen is made flat with location tabs for tensioning, then the screen can be installed in the sifter, but sealing efficiency decreases over time leading to product loss and premature screen failure
Solution Approach 1:
The sealing mechanism transitions from rigid location tabs to elastic members that can dynamically adjust contact pressure parameters. The elastic members maintain consistent sealing force over time, compensating for wear and frame movement, thereby preventing the degradation of sealing efficiency that occurs with rigid tab systems.
Data Source
AI summary
A screen for a gyratory sifter including a frame having a plurality of cross-members and a rigid external extension. Additionally, the screen including a filtering element securably attached to the frame. Also, a method for installing a pre-tensioned screen in a gyratory sifter including inserting the pre-tensioned screen into the gyratory sifter. The pre-tensioned screen including a frame having a plurality of cross-members and a rigid external extension and a filtering element securably attached to the frame. Additionally, the method including mating the pre-tensioned screen to a ball box, wherein the mating includes placing the pre-tensioned screen against a contoured section of the ball box, and securing the pre-tensioned screen with a screen plate.