Rotor Wing Tip Helix Angle Variation for Mixer Flow
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Solution Overview
Problem
Tangential internal batch mixers face limitations in mixing efficiency due to the fixed wing tip geometry of traditional rotors, which restricts the range of materials that can be effectively mixed and fails to optimize material flow components like gap, side, and front flow.
Innovation Solution
The rotor design features a wing tip surface with varying helix angles along its length, providing a tapered shape that enhances mixing capabilities by offering both narrow and wide wing tip benefits, allowing for greater material compatibility and improved flow components, along with additional features like coolant channels for enhanced temperature control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a rotor with fixed wing tip geometry is used, then the structure is simple and easy to manufacture, but the mixing efficiency is limited and material compatibility is restricted
Solution Approach 1:
The wing tip surface is designed with varying helix angles along its length, creating different local flow characteristics at different positions. The leading edge has a first helix angle while the trailing edge has a second helix angle, allowing optimization of material flow components (gap flow, side flow, front flow) at different locations simultaneously.
Solution Approach 2:
The wing geometry is designed to dynamically adapt to different materials being mixed. The varying helix angles create a tapered wing tip surface that can accommodate different material viscosities and flow characteristics, allowing the same rotor to efficiently mix a wide range of materials without requiring geometric changes.
2Productivity
If a rotor with fixed wing tip geometry is used, then the manufacturing process is simple, but the mixing efficiency and material flow optimization are limited
Solution Approach 1:
The invention changes the geometric parameters of the wing tip surface by varying the helix angle from the leading edge to the trailing edge. This parameter variation creates a tapered surface that optimizes material flow components, improving mixing efficiency while remaining manufacturable through standard rotor fabrication processes.
3Temperature
If traditional rotor design is used, then the structure is simple, but temperature control is insufficient and hot spots occur
Solution Approach 1:
Coolant channels are strategically positioned within the rotor structure, particularly in regions where heat generation is highest during mixing. This localized cooling approach targets hot spots directly while maintaining overall rotor functionality and minimizing the complexity of the cooling system.
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
This design improves mixing efficiency by accommodating a wider range of materials and optimizing material flow, while also providing better temperature control and reduced risk of hot spots through increased wing tip surface area and strategic coolant channel placement.
Implementation Method 1
coolant channels for enhanced temperature control
Implementation Method 2
strategic coolant channel placement
Data Source
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AI summary
A rotor (501) for use in a tangential internal batch mixer, the rotor comprising a main body (502) configured to rotate about a rotor axis (503), a wing (504) extending from the main body, and arranged helically about a portion of the main body, the wing (504) comprising a wing tip surface (509), a first portion (509a) of the wing tip surface extending between a first edge (530) and a second edge (531) of the wing; wherein the first edge (530) comprises a first helix angle (α) and the second edge (531) comprises a second helix angle (β), the first helix angle being different to the second helix angle.