Screw Separator Wearing Ring for Strainer Basket Wear Reduction

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Solution Overview

Problem

Existing screw separators for dewatering solids suffer from high wear and require frequent inspection and replacement of the strainer basket due to high stresses, leading to increased maintenance costs and reduced durability.

Innovation Solution

A screw separator design where the screw vanes terminate in a replaceable wearing ring downstream of the strainer basket, reducing stress on both the screw vanes and the strainer basket, and incorporating a wearing ring made of a soft material that can deflect to absorb pressure, along with armor-coated screw vanes for enhanced durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the screw vanes terminate in the strainer basket to maintain a narrow gap for efficient dewatering, then dewatering efficiency is improved, but wear to the strainer basket and screw vanes increases due to high stresses

Engineering Contradiction:

Improvedewatering efficiencyVSAvoidservice life of strainer basket

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system is segmented into distinct functional zones: the strainer basket for filtration, a wearing ring as a sacrificial component, and the screw vanes for dewatering. This segmentation allows the wearing ring to absorb wear and stress, protecting the strainer basket while maintaining the narrow gap required for efficient dewatering operation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The wearing ring acts as an intermediary component positioned between the screw vanes and the strainer basket. It mediates the high-stress interaction by providing a replaceable surface that absorbs wear, thereby protecting the strainer basket from direct contact stresses while allowing the screw vanes to maintain their positioning for effective dewatering.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If the strainer basket is made robust to withstand high stresses, then durability is improved, but manufacturing complexity increases due to the filter rod structure

Engineering Contradiction:

Improvedurability of strainer basketVSAvoidmanufacturing complexity of filter structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The high-stress bearing function is extracted from the strainer basket and transferred to the wearing ring. This allows the strainer basket to be designed purely for its filtration function using the simpler filter rod structure, while the wearing ring handles the mechanical stresses, thereby reducing manufacturing complexity of the strainer basket while maintaining durability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The wearing ring is designed as a sacrificial, replaceable component that absorbs wear and stress. Instead of making the entire strainer basket robust and complex, a simpler, cheaper wearing ring is used that can be easily replaced when worn, reducing the overall manufacturing complexity while maintaining system durability.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If regular inspection and replacement of the strainer basket is performed, then operational reliability is maintained, but maintenance costs and downtime increase

Engineering Contradiction:

Improveoperational reliabilityVSAvoidmaintenance downtime

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system is divided into a permanent strainer basket and a replaceable wearing ring. This segmentation allows only the wearing ring to be inspected and replaced during maintenance, while the strainer basket remains in place, significantly reducing maintenance downtime and costs while maintaining operational reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The wearing ring serves as an intermediary that protects the strainer basket from wear. Since the wearing ring is designed to be replaced rather than the strainer basket, maintenance operations are simplified to only involve the wearing ring, reducing both maintenance time and costs while ensuring continued operational reliability.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 design significantly extends the service life of the strainer basket, reduces maintenance needs, and lowers operational costs by allowing for easy replacement of the wearing ring, while maintaining efficient dewatering performance.

Implementation Method 1

a screw separator or a screw press separator for separating solids out of suspensions

Methodology Applied

Scientific EffectMechanical dewatering:

Implementation Method 2

able to deflect away from the screw vanes by way of slight elastic deformation

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS9162411B2Screw separator

Publication Date: 2015.10.20 UTS BIOGASTECHN

AI summary

A screw separator for separating solids out of suspensions, having at least one housing and at least one feed pipe for the suspension, at least one discharge pipe for liquids, and at least one outlet for the at least partially dewatered solids. At least one strainer basket is provided in the housing in which a screw is rotatably mounted, and the screw vanes terminate in a replaceable wearing ring mounted downstream of the strainer basket.