Screw Conveyor Flight Geometry for Lower Wear in Dewatering Separators
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Solution Overview
Problem
Existing separator devices with conveyor snails experience high maintenance efforts and friction energy losses due to wear on the snail wing and cylinder sieve, leading to reduced performance and increased energy consumption.
Innovation Solution
A conveyor snail with a metallic structure, manufactured using additive manufacturing, features a snail wing with a cross-sectional profile that widens radially outward and includes recesses for fiber absorption, reducing friction and wear by creating a brush-like surface for continuous cleaning of the sieve device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a cylindrical screen with thinnest possible walls is used, then filtration efficiency is improved, but wear on the screw flights and screen leads to reduced throughput
Solution Approach 1:
The patent changes the geometric parameters of the screw flight by adding a radially outward extending edge portion that widens toward the outer circumference. This creates a brush-like surface structure that actively cleans the screen during rotation, preventing clogging and reducing wear on both the screw flight and screen, thereby maintaining throughput while preserving filtration efficiency
Solution Approach 2:
The invention introduces a dynamic cleaning mechanism where the radially outward edge portion of the screw flight continuously contacts and scrapes the cylindrical screen during rotation. This dynamic interaction automatically removes accumulated material from the screen surface, preventing clogging and reducing wear without requiring additional cleaning components
2Manufacturing precision
If clearing elements with fibrous materials are used to clean screen openings, then screen clearing is improved, but friction between fibrous materials and cylinder sieve increases wear and energy consumption
Solution Approach 1:
The patent extracts and eliminates the separate clearing element with fibrous materials from the system. Instead, the cleaning function is integrated directly into the screw flight structure itself through the radially outward extending edge portion, which performs screen cleaning through its geometric design rather than through friction-based fibrous contact
Solution Approach 2:
The invention replaces the friction-based mechanical cleaning mechanism (fibrous materials rubbing against the screen) with a geometric scraping mechanism. The radially outward edge portion of the screw flight acts as a rigid scraper that removes material through controlled contact, reducing frictional energy losses while maintaining effective screen clearing
3Ease of manufacture
If conventional manufacturing methods are used for screw conveyors, then manufacturing simplicity is maintained, but maintenance effort increases due to wear
Solution Approach 1:
The patent modifies the geometric parameters of the screw flight by incorporating a radially outward extending edge portion that widens toward the outer circumference. This design change creates a self-cleaning brush-like surface that reduces wear on both the screw conveyor and screen, extending component lifespan and reducing maintenance frequency without complicating the manufacturing process
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 reduces friction losses and wear on the sieve device, decreases the energy required to operate the conveyor snail, and extends the lifespan of components, while also minimizing material usage and costs.
Implementation Method 1
the screw vane has a cross-sectional profile that widens radially outward from the inner to the outer circumference and, in particular, has several spaced-apart recesses on its outer circumference for receiving fibrous materials
Data Source
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AI summary
The invention relates to a screw conveyor comprising a shaft extending axially along an axis of rotation, a screw flight arranged helically around the shaft, connected to the shaft at its outer circumference, and extending axially along at least one section of the shaft, wherein the screw flight has an outer edge at its outer circumference and has at least one recess for receiving fibrous materials in its outer edge, wherein the screw flight has a cross-sectional profile with a width in the region of its outer circumference and a width in the region of its inner circumference, and the width in the region of its outer circumference is greater than the width in the region of its inner circumference.Furthermore, the invention relates to a separator device for dewatering moist masses, in particular slurry residues and/or digestate, as well as a method for the additive manufacturing of a screw conveyor and a use of a screw conveyor.