Reusable Disc Screen With Replaceable Wear Coating
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Solution Overview
Problem
Existing material sorting systems face inefficiencies and high costs due to frequent replacement of disc screens, which are subject to wear and require costly reconfiguration for altering separation methods or replacing worn-out components.
Innovation Solution
A disc assembly with a removable and reusable design featuring a textured transport surface coated with a replaceable wear material, allowing for easy detachment and reapplication, reducing wear and tear, and extending the life of the disc core while minimizing replacement costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If discs are welded to the shaft, then the disc assembly has high strength and reliability, but the entire shaft requires periodic replacement when discs wear out
Solution Approach 1:
The disc assembly is segmented into a shaft portion and a disc portion that can be independently replaced. The disc portion is detachably connected to the shaft portion, allowing the disc to be replaced without replacing the entire shaft assembly. This segmentation enables selective replacement of only the worn component (disc) while preserving the still-functional shaft.
Solution Approach 2:
The patent enables recovery and reuse of the shaft portion after the disc portion wears out. Instead of discarding the entire welded assembly, the functional shaft is recovered and reused with a new disc, reducing material waste and replacement costs.
2Duration of action of stationary object
If discs are fastened using bolts or compression fittings, then the shaft can be reused for a longer period of time, but replacement of discs is expensive and time consuming
Solution Approach 1:
The disc assembly is divided into separable shaft and disc portions with a detachable connection interface. This segmentation allows rapid removal and replacement of the disc portion without complex fastening operations, significantly reducing replacement time while maintaining shaft reuseability.
Solution Approach 2:
The connection between the disc and shaft is made dynamic and adjustable rather than fixed. The detachable connection mechanism allows for quick assembly and disassembly operations, enabling maintenance personnel to replace discs rapidly without time-consuming bolting or compression operations.
3Loss of time
If the disc assembly is designed for easy replacement, then maintenance time is reduced, but the structural complexity of the disc assembly increases
Solution Approach 1:
The disc assembly is segmented into modular shaft and disc portions with a standardized detachable connection. This modular segmentation simplifies the overall structure by eliminating the need for complex welding or fastening systems, while the standardized interface reduces maintenance time through quick connect/disconnect operations.
4Ease of manufacture
If worn-out equipment is disposed of or stored, then the system is ready for new components, but operational efficiency is reduced during replacement
Solution Approach 1:
The detachable connection design allows the disc portion to be pre-prepared and replaced in a straightforward sequence without complex disassembly or system shutdown procedures. This preliminary preparation of the replacement interface minimizes downtime and maintains operational efficiency during component replacement.
Data Source
AI summary
A disc assembly with a substantially rigid disc core includes a first section removably attached to a second section and mounted to a disc screen shaft. The disc core includes a transport surface extending between a left side of the disc core and a right side of the disc core, and a replaceable coating of textured wear material is deposited along the transport surface.