Segmented Filter Housing for Roller Washer Particle Removal
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Solution Overview
Problem
Existing filters for nozzle roller washing systems are inadequate in removing particles larger than 1.5mm from flood water, leading to clogging issues and high operating costs due to the need for frequent replacements and high-pressure resistance.
Innovation Solution
A filter design featuring a filter housing with a sieve basket that filters only a portion of the flood water, allowing filtered water to flow through a separate line while unfiltered water carries away contaminants, thus preventing clogging and reducing pressure requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a filter is installed shortly before the jet roller wash to prevent nozzle blockages, then particle removal effectiveness is improved, but the filter becomes expensive and requires frequent replacement due to high pressure exposure
Solution Approach 1:
The filter system is divided into two functional parts: a first filter component (strainer basket) that removes large particles under low pressure, and a second filter component (fine mesh filter) that removes smaller particles under high pressure. This segmentation allows each component to be optimized for its specific function, reducing the cost and complexity of any single filter while maintaining overall reliability
Solution Approach 2:
The first filter acts as an intermediary element between the water source and the second filter. By pre-filtering large particles at low pressure, it protects the second filter from rapid clogging and reduces the frequency of maintenance, thereby lowering overall operating costs while maintaining particle removal effectiveness
2Reliability
If a filter is positioned in the high-pressure water stream downstream of the pump, then particle removal effectiveness is improved, but the filter requires frequent replacement and incurs high operating costs
Solution Approach 1:
The first filter performs preliminary filtration of large particles before the water reaches the second filter and the jet roller wash nozzles. This preliminary action prevents rapid accumulation of debris in the second filter, extending its service life and reducing downtime for filter replacements while maintaining effective particle removal
Solution Approach 2:
The filtration system is segmented into two stages: coarse filtration (first filter) and fine filtration (second filter). This segmentation distributes the filtration load, preventing any single filter from becoming overwhelmed and requiring frequent replacement, thus reducing operational downtime
3Adaptability or versatility
If a filter is designed to withstand high pressure of 10-11 bar, then it can be positioned downstream of the pump, but the filter becomes very expensive to manufacture
Solution Approach 1:
The filter system is segmented into a first filter designed for low-pressure operation and a second filter designed for high-pressure operation. This allows the first filter to be manufactured at lower cost with simpler materials, while only the second filter (which handles high pressure) requires expensive high-pressure-rated components
Solution Approach 2:
Different parts of the filtration system have different pressure requirements. The first filter operates in a low-pressure zone and is constructed with simpler, cheaper materials, while the second filter operates in a high-pressure zone and uses more robust, expensive materials. This local differentiation of quality matches the actual operational requirements of each component
4Reliability
If the filter processes the entire volume flow of flume water, then particle removal effectiveness is improved, but the filter becomes complex and expensive
Solution Approach 1:
The filtration system is segmented into two separate filter components arranged in series, each handling different particle sizes and pressure conditions. This segmentation allows each filter to be simpler in design while collectively achieving comprehensive particle removal that would be complex in a single-filter 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
The filter effectively removes particles larger than 1.5mm, extends the operational time of the nozzle roller washing system by reducing downtime for filter replacements, and lowers costs due to its inexpensive manufacturing and reduced pressure requirements.
Implementation Method 1
a strainer basket (6) is arranged in the filter housing (4) between the inlet (2) and the outlet (3), through which parts of the flume water flow, filter this as it flows through
Implementation Method 2
The filtered particles that do not penetrate the strainer basket towards the filtrate outlet are at least partially absorbed by the unfiltered flume water and discharged from the filter through the filter outlet together with the unfiltered flume water
Implementation Method 3
The unfiltered portion of the flume water discharged from the outlet, along with the contaminants retained by the strainer basket, is discharged through the outlet back into the clarifier
Data Source
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AI summary
The invention relates to a filter for a jet roller washer for removing impurities from field crops with a particle size of at least 1.5 mm in diameter, wherein the filter (1) has a filter housing (4) with an inlet (2) arranged at or near the first end region and an outlet (3) arranged at or near the opposite second end for unfiltered wash water, wherein a sieve basket (6) is arranged in the filter housing (4) between an inlet and an outlet, through which parts of the wash water flow, filtering it as it flows through, and discharges through a filtrate outlet (7), through which only wash water filtered by the sieve basket (6) flows, to the piping system for supply to the jet roller washer, wherein means for cleaning the sieve basket (6) are arranged inside the filter housing (4).