Abrasion Resistant Pulse Nozzle Tungsten Carbide Coating
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Solution Overview
Problem
Existing pulse nozzle systems in storage devices and silos suffer from abrasion on technology walls and frequent component replacement due to deflated compressed air and abrasive material interaction, leading to high maintenance needs and short component lifespan.
Innovation Solution
An abrasion-resistant pulse nozzle design featuring a tungsten carbide layer up to 1mm thickness on the piston head body and a metal sheet with a tungsten carbide layer up to 1mm on the pulse nozzle body, combined with a securing member and elastic components to enhance durability and prevent material fatigue.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional pulse nozzle components are used, then the system is simple and cost-effective, but the components suffer from high abrasion and short lifespan
Solution Approach 1:
The patent applies composite materials by coating the piston head body with a wear-resistant material layer (such as tungsten carbide or ceramic coating). This combines the mechanical properties of the base metal with the abrasion resistance of the coating material, extending component lifespan while maintaining the original nozzle structure's simplicity
Solution Approach 2:
The wear-resistant coating is applied locally only to the piston head body surface that contacts abrasive materials, rather than coating the entire nozzle assembly. This provides enhanced durability precisely where needed while minimizing additional complexity and cost
2Productivity
If pulse nozzles are used to release stored materials, then material flow is improved, but abrasion occurs on the storage vessel walls around the nozzle
Solution Approach 1:
The pulse nozzle acts as an intermediary device that introduces compressed air pulses to fluidize and move materials without requiring direct mechanical contact between moving parts and the storage vessel walls. This mediator approach enables material flow while protecting walls from abrasion
Solution Approach 2:
The system uses compressed air pulses delivered through the nozzle to create pneumatic pressure that moves materials along the storage vessel walls. This pneumatic mechanism replaces mechanical scraping or pushing, enabling material flow while eliminating direct mechanical abrasion of the walls
3Productivity
If the piston head body is made larger to handle higher flows, then productivity increases, but abrasion and wear increase proportionally
Solution Approach 1:
By coating the piston head body with wear-resistant materials, the system can use larger piston dimensions to handle higher material flows without proportionally increasing wear. The coating protects the expanded surface area from abrasion, allowing productivity gains without corresponding increases in material loss
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 significantly reduces wear and tear, extending the lifespan of pulse nozzle components and minimizing the need for repairs and replacements, while maintaining effective material flow and discharge without damaging storage vessel walls.
Implementation Method 1
the piston head body front is provided with an abrasion resistant layer
Implementation Method 2
an elastic member between the first holder attached to the piston and the second holder attached to the pulse nozzle body
Implementation Method 3
compressed air energy in pulse nozzles... the pulse nozzles reduce the external friction angle... resulting in releasing stuck or deposited loose materials
Data Source
Figure 1~2
Figure 3
AI summary
The object of the invention is an abrasion resistant pulse nozzle comprising a pulse nozzle body, a piston with piston head body moveably located inside the pulse nozzle body, an elastic member between a first holder attached to the piston and a second holder attached to the pulse nozzle body where the piston head body front is provided with an abrasion resistant layer and further is substantial a system for flow of bulk materials in vessels such as storage devices or silos comprising at least one abrasion resistant pulse nozzle connected to the compressed air source, and at least one solenoid valve connected to the control unit with an electric cable, or multiple pulse nozzles to the central control system including the designing of various activities algorithm variations.