Rotating Impeller Suction Device with Upstream Separator
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Solution Overview
Problem
Existing particle removal systems for processing machines, particularly in non-metallic material industries, face challenges such as high energy consumption, noise emissions, and susceptibility to damage from larger chips or foreign bodies due to imbalance and direct impact on turbine elements and spindle bearings.
Innovation Solution
A discharge device with an impeller that generates an air flow for particle removal, preceded by a separator to filter out larger particles, which is rotationally fixed to the processing means, reducing energy consumption and noise while preventing damage from larger particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a spindle suction device is used for particle removal, then particles can be removed from the processing area, but large suction air volume flows are required leading to high energy costs and noise emissions
Solution Approach 1:
The suction device is positioned directly at the particle generation point (cutting edge), creating a localized suction zone. This allows effective particle removal with minimal air volume flow, reducing energy consumption and noise emissions compared to centralized suction systems that require high flow rates to reach distant collection points.
Solution Approach 2:
The suction function is segmented from the main processing tool, with a separate impeller-based suction device integrated at the cutting edge. This segmentation allows independent optimization of suction performance without affecting the main spindle's power consumption, enabling localized particle capture with low energy input.
2Reliability
If turbine elements are used to support dust extraction during machining, then dust extraction is improved, but larger chips or residual parts can be sucked in leading to imbalances and destruction of turbine elements or damage to spindle bearings
Solution Approach 1:
A separator is installed upstream of the impeller to pre-filter the air stream before it reaches the suction device. This preliminary action removes larger chips and foreign bodies from the air flow, preventing them from entering the impeller and causing imbalances or damage, while still allowing effective dust extraction.
Solution Approach 2:
The separator acts as an intermediary component between the processing area and the impeller. It mediates the air flow by filtering out harmful particles while allowing the suction function to operate, thus protecting the impeller and spindle bearings from damage without compromising dust extraction effectiveness.
3Ease of manufacture
If an impeller rotates with the processing means in a rotationally fixed manner, then the construction is simplified and cost-effective, but the impeller must withstand varying particle loads and imbalances
Solution Approach 1:
The separator is positioned to pre-filter particles before they reach the impeller, reducing the particle load and minimizing the risk of imbalance. This preliminary filtering action protects the rotationally fixed impeller from damage while maintaining the simplified construction design.
Solution Approach 2:
The separator creates a localized protection zone around the impeller by filtering particles in the incoming air stream. This local quality improvement ensures that the impeller operates in a cleaner environment, reducing wear and imbalance risks while maintaining the overall simplicity of the rotationally fixed construction.
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 effectively reduces energy costs and noise emissions by generating a sufficient suction effect near the particle origin, preventing damage to turbine elements and spindle bearings, and ensuring operator safety by filtering out larger particles before they reach the impeller.
Implementation Method 1
an impeller (2) that is set up to generate an air flow for discharging particles
Implementation Method 2
a separator (5) which removes particles from the air sucked in by the impeller (2) before the air passes through the impeller (2)
Data Source
Figure 1~2
AI summary
The device (1) has an impeller wheel (2) generating air flow for removing particles, which are developed during machining by a machining tool. The impeller wheel is attached at the machining tool in a rotation-fixed manner such that the impeller wheel is rotated around a machining axle by the machining tool. A separator (5) is arranged upstream to the impeller wheel, and separates the particles from air before passing the impeller wheel, where the air is sucked by the impeller wheel. The separator is attached at a tool shaft of the machining tool.