Recycled Abrasive Drying Chamber with Vibrating Mesh
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Solution Overview
Problem
Current abrasive recycling and drying processes are inefficient, requiring continuous operation, high energy consumption, and manual intervention, leading to equipment damage and increased costs due to the need for continuous personnel and high electric input, with existing systems unable to optimally manage abrasive dosing and drying capacity.
Innovation Solution
A novel drying system for recycled abrasive using a vibrating mesh and waste heat recovery, with automatic control and programmable machinery, allowing for continuous operation without manual attendance, optimizing abrasive dosing and drying capacity through efficient air flow and temperature management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If electric heating coils are used in the drying kiln, then drying capacity is achieved, but energy consumption increases and coils are damaged by abrasive residues
Solution Approach 1:
The patent changes the heating method from direct electric coil heating to indirect heating using a heat-exchange system where hot air is generated externally and circulated through the drying kiln. This parameter change eliminates direct contact between heating elements and abrasive residues, preventing coil damage while maintaining drying capacity through controlled air temperature and flow.
Solution Approach 2:
The patent introduces hot air as an intermediary medium to transfer thermal energy from the abrasive to the material being dried. Instead of direct electric coil heating, the system generates hot air externally, circulates it through the drying chamber, and uses this intermediary gas phase medium to achieve drying without direct contact between heating elements and abrasive residues.
2Ease of operation
If manual operation is used for abrasive dosing and raking, then control is possible, but labor requirements increase and continuous operation is difficult
Solution Approach 1:
The patent implements automatic dosing systems and mechanical raking devices that operate autonomously within the drying kiln. The system self-regulates abrasive distribution and prevents caking through automated mechanical action, eliminating the need for continuous manual intervention while maintaining precise control over the drying process.
Solution Approach 2:
The patent replaces manual mechanical operations with automated mechanical systems including dosing mechanisms and raking devices that are integrated into the drying kiln. These automated mechanical systems perform functions previously requiring human labor, enabling continuous operation without manual attendance.
3Speed
If high temperature drying is used, then drying speed increases, but abrasive sinters on heating coils and equipment damage occurs
Solution Approach 1:
The patent uses hot air circulation as an intermediary to transfer thermal energy without direct contact between high-temperature heating elements and abrasive residues. The hot air medium provides sufficient drying temperature while preventing sintering that occurs with direct coil heating, as the thermal energy is distributed through convection rather than direct radiant or conductive heating.
Solution Approach 2:
The patent changes the heating mechanism from direct high-temperature coil heating to controlled hot air circulation. This parameter change allows maintaining effective drying temperature while distributing heat more uniformly and preventing localized overheating that causes sintering and equipment damage.
4Productivity
If continuous operation is required, then productivity is maintained, but manual intervention and energy consumption increase
Solution Approach 1:
The patent implements automated dosing and mechanical raking systems that enable the drying kiln to operate continuously without manual intervention. The self-service automated systems maintain consistent abrasive distribution and prevent caking, allowing uninterrupted operation with reduced energy consumption compared to manual operation.
Solution Approach 2:
The patent designs the drying system to maintain continuous useful action through automated feed mechanisms and circulation systems. The hot air circulation and abrasive dosing operate continuously without interruption, maintaining productivity while reducing the energy associated with manual intervention and batch processing.
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 system achieves a significant reduction in energy consumption, extends mesh lifespan, and increases drying capacity to 30-60 kg/hour, with the ability to operate unattended, ensuring the recycled abrasive is ready for immediate use in water jet cutting processes.
Implementation Method 1
Air flow occurs in space (16) between the wall of drying chamber (5) and the wall of collecting vessel (13) and it lifts and aerates recycled abrasive grains
Implementation Method 2
Vibrating mesh (12) shakes grains of recycled abrasive and they move along perimeter of drying chamber (5)
Implementation Method 3
Drying chamber (5) is placed in air flow (E) which flows upwards with speed 0.7 to 1.2 m/s and under transport pressure 350 to 450 Pa
Implementation Method 4
There is cyclone separator (9) on outlet from drying chamber (5) to remove small dust from outlet air (F)
Data Source
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AI summary
Drying of recycled abrasive (21) that can be recycled separated or as a part of the full recycling system. Sorted and meshed wet recycled abrasive is kept in a hopper (3) for wet recycled abrasive, it is continuously delivered using a screw feeder (4) into a drying chamber (5) on a vibration mesh (12). Air is blown (E) in the chamber, using an air flow generator (6), under a vibration mesh. The recycled abrasive is moved and lifted on the mesh using air flow and mesh vibration, this provides for clots of recycled abrasive to break down to particles of recycled abrasive and abrasive mixes and dries.