Reverse-Flow Screw Conveyor for Melt Filter Backwashing
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Solution Overview
Problem
Existing melt filter systems face challenges in reliably backwashing, especially with large impurity particles, and are prone to clogging and pressure peak issues, which can lead to partial melt degradation and reduced efficiency.
Innovation Solution
A melt filter arrangement utilizing a continuous screw conveyor device within the backwash channel to generate a flushing flow, allowing for reliable conveyance of melts with coarse impurities without blocking or damaging components, and enabling independent control of pressure, flow rate, and flow velocity, separate from the melt channel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a gear pump is used to convey melt for backwashing, then the melt filter can be cleaned, but the system becomes unreliable when large impurity particles are present
Solution Approach 1:
The harmful gear pump mechanism is extracted from the backwashing system and replaced with a screw conveyor. This removes the source of reliability problems while maintaining the backwashing function. The screw conveyor specifically extracts only the necessary conveying function without the clogging and pressure spike issues of gear pumps.
Solution Approach 2:
The screw conveyor components are designed to be simple and replaceable, particularly the screw flight itself which can be easily replaced if damaged by impurities. This approach accepts that impurity damage may occur but minimizes the consequence through simple, low-cost replacement rather than complex, expensive repairs.
2Power
If a gear pump is used for backwashing, then melt can be conveyed, but pressure spikes occur causing melt degradation
Solution Approach 1:
The gear pump mechanical system is replaced with a screw conveyor mechanical system. The screw conveyor provides continuous, gradual pressurization rather than the intermittent, high-impact pressure spikes characteristic of gear pumps. This substitution maintains melt conveyance power while eliminating the harmful pressure fluctuations.
3Reliability
If traditional backwashing systems are used, then filtering can occur, but the system requires complex synchronization of multiple actuators
Solution Approach 1:
The complex synchronized actuator system is extracted and replaced with a single screw conveyor mechanism. This removes the need for multiple actuators and their synchronization while maintaining the backwashing function. The screw conveyor performs both conveyance and pressurization in a single integrated component.
4Productivity
If gear pumps are used for backwashing, then melt flow can be generated, but the conveying channels become clogged at dead zones
Solution Approach 1:
Instead of using a gear pump that creates dead zones where melt stagnates and clogs, the screw conveyor is used which maintains continuous forward motion throughout the entire conveying channel. The screw flight design ensures that all areas of the channel remain active and free of stagnant zones, preventing clogging while maintaining backwashing 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 ensures effective backwashing of melt filters, preventing clogging and maintaining efficiency even with pressure peaks, while allowing for continuous operation and adjustable flow parameters, enhancing the reliability and longevity of the melt filter system.
Implementation Method 1
a conveying device in the form of a screw conveyor (34) which is located in the backwash channel (30) and is used to generate a flushing flow
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
Described is a melt filter arrangement (10) comprising a melt channel (20), a reverse-flow channel (30), and a screen device (40) for filtering melt in the melt channel (20). The melt channel (20) and the reverse-flow channel (30) extend through the screen device in different areas (23, 33) of the screen device (40). The melt filter arrangement (10) further comprises a reverse-flow screw conveyor device (34, 34') within the reverse-flow channel (30). As a continuous conveying element, said reverse-flow screw conveyor device (34, 34') generates or defines the current in the reverse-flow channel (30).