Electric Pulse Fragmentation Circuit for Reliable Quartz Breakage
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Solution Overview
Problem
Existing methods for electrically fragmenting materials, such as quartz, are inefficient and costly due to the use of outdated Marx pulse generators, which fail frequently and require high maintenance, and do not effectively break materials along impurity boundaries, leading to inefficient energy consumption and increased operational costs.
Innovation Solution
A device and method utilizing a high-voltage pulse transformer, storage capacitor, and IGBT modules to generate controlled electrical pulses with a duration of 10-20 microseconds and an electric field intensity of 300 kV/cm, allowing fragmentation along crystal and impurity boundaries, with a continuous processing capability and reduced maintenance needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If Marx pulse generators are used to generate high-voltage pulses for material fragmentation, then electric field intensity can be achieved, but the device reliability deteriorates due to frequent failures and high maintenance requirements
Solution Approach 1:
The patent replaces the mechanical Marx pulse generator system with an electronic switching system using IGBT modules and control circuits. This substitution eliminates the mechanical wear and failure modes of traditional pulse generators while maintaining the required high-voltage pulse generation capability, thereby improving reliability without sacrificing electric field intensity.
Solution Approach 2:
The patent changes the operating parameters of the pulse generation system by using modern IGBT technology with controlled switching times and duty cycles. This allows for optimized pulse width, frequency, and voltage levels that reduce stress on components while maintaining effective fragmentation fields, thus improving device reliability.
2Force
If conventional electrodynamic acting methods are used for material fragmentation, then shock waves can be generated within the material, but the manufacturing precision deteriorates because fractures do not follow impurity boundaries
Solution Approach 1:
The patent applies local quality by creating non-uniform electric field distributions that concentrate stress at specific locations corresponding to impurity boundaries within the material. The electric field intensity is modulated spatially to match the internal structure of the material, causing fractures to preferentially occur along desired boundaries rather than randomly throughout the material.
Solution Approach 2:
The patent uses periodic pulsed electric fields with specific duty cycles and frequencies that resonate with the material's internal structure. This periodic action allows cumulative stress buildup at impurity interfaces while protecting the bulk material, enabling precise fracture control along boundaries over multiple pulse cycles.
3Power
If Marx pulse generators are used for material processing, then high-voltage pulses can be generated, but the energy efficiency deteriorates due to high inductance and excessive energy consumption
Solution Approach 1:
The patent replaces the inductive Marx generator architecture with a capacitive energy storage system discharged through solid-state IGBT switches. This eliminates the high inductance inherent in Marx generators, reducing energy losses during switching and allowing more efficient energy transfer to the workpiece, thereby lowering overall energy consumption while maintaining high power output.
Solution Approach 2:
The patent optimizes energy parameters by using controlled pulse widths, adjustable duty cycles, and regulated voltage levels matched to the specific material being processed. This prevents excessive energy application and allows the system to operate at minimum required power levels, significantly improving energy efficiency compared to the fixed-parameter Marx generator approach.
4Reliability
If traditional crushing and grinding methods are used for quartz purification, then impurities can be removed, but the productivity deteriorates due to multiple processing steps and high operational costs
Solution Approach 1:
The patent extracts and removes impurities from quartz through direct electric field-induced fracture along impurity boundaries. This single-step extraction process eliminates the need for multiple sequential operations (crushing, grinding, washing, screening), dramatically improving processing efficiency while maintaining purification effectiveness by selectively fracturing only at impurity locations.
Solution Approach 2:
The patent replaces mechanical crushing and grinding systems with an electric field-based fragmentation system. This substitution eliminates the need for heavy machinery, multiple processing stages, and associated operational costs, while achieving the same purification goal in a single pass, thereby significantly boosting productivity.
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 efficient fragmentation of materials like quartz with lower energy consumption, reduced maintenance intervals, and continuous operation, producing a desired crushed product size with minimal labor and cost.
Implementation Method 1
create an electric field intensity of more than 300 kV/cm
Implementation Method 2
exploit the relatively low tensile strength of the material and the natural boundaries between the crystal and impurities
Implementation Method 3
a shock wave is generated within the material itself
Data Source
AI summary
An electric pulse fragmentation device and method are provided, the device comprising a pulse transformer, one or more buffer capacitors, a plurality of IGBT modules, a storage capacitor, a spark gap, and a fragmentation chamber, the spark gap being defined by spark gap first and second electrodes, the fragmentation chamber comprising fragmentation chamber first and second electrodes. The buffer capacitors are electrically connected to a voltage rectifier. The buffer capacitors are charged by electrical current received from the voltage rectifier. The IGBT modules control partial discharge of the buffer capacitors to permit and restrict current flow from the buffer capacitor to transformer primary windings for a duration of a control pulse. The storage capacitor is charged by electrical current from transformer secondary windings. The storage capacitor is adapted to discharge current across the spark gap to the fragmentation chamber electrodes. Raw material positioned between fragmentation electrodes can be fractured.