Self-Cleaning Magnetic Shaft Cylinder
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Solution Overview
Problem
Magnetic separators in processing industries face challenges such as bulkiness, high space requirements, uneven actuation leading to jerking effects, and reduced magnetic force due to the use of sleeves, which decreases separation efficiency for modern contamination like work-hardened steel fragments and magnetic stone.
Innovation Solution
A self-contained magnetic separation module with a cylinder and piston system that allows incremental rotation of each magnet bar, eliminating the need for external actuation and sleeves, enabling direct exposure of magnetic shafts to the material flow for effective separation and self-cleaning without external wiping glands or chambers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a single large pneumatic cylinder is used to push or pull a grate magnet through a rack of cleaning glands, then the magnetic separator can be actuated, but the size and bulkiness of the machinery increases and more space is required
Solution Approach 1:
The single large pneumatic cylinder is divided into multiple smaller pneumatic cylinders (at least two) that operate independently or in coordination. Each smaller cylinder actuates a corresponding grate magnet, reducing the overall size and space requirements while maintaining the actuation capability. This segmentation allows the system to achieve the same functional outcome with reduced bulkiness.
2Volume of moving object
If two or more smaller pneumatic cylinders are used to push or pull a grate magnet, then the machinery size is reduced, but it becomes difficult to correctly synchronise the actuation and causes uneven or jerky movement
Solution Approach 1:
The system incorporates feedback mechanisms where the actuation of each pneumatic cylinder is monitored and coordinated to ensure synchronous operation. This feedback control allows the multiple smaller cylinders to operate in unison, eliminating jerky movements and ensuring smooth actuation of the grate magnets while maintaining the reduced machinery size advantage.
3Reliability
If an independent cleaning annular wiper bushing is attached to a bulk head or wall of a fixed magnetics discharge chamber, then magnet cleaning is effected, but the device complexity and manufacturing cost increase
Solution Approach 1:
The cleaning function is merged with the existing grate magnet structure itself. The grate magnets are designed to be self-cleaning through their inherent movement and configuration, eliminating the need for separate cleaning mechanisms like annular wiper bushings attached to bulk heads. This integration reduces device complexity and manufacturing cost while maintaining effective cleaning capability.
4Ease of operation
If magnetic tubes or bars are independently connected to a conventional non magnetic shaft, then the magnetic separator can be actuated, but cleaning requires external wiping glands or chambers which increase device complexity
Solution Approach 1:
The magnetic tubes or bars are designed to be self-cleaning through their own movement and configuration during operation. The grate magnets move in a manner that allows them to clean themselves without requiring external wiping glands or chambers. This self-service approach eliminates complex external cleaning mechanisms while maintaining effective magnet cleaning capability.
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 solution provides a compact, efficient, and self-powered magnetic separation system that enhances separation efficiency, reduces manufacturing costs, and minimizes wear and tear, effectively handling modern contamination types without the need for bulk heads or fixed centers, ensuring continuous operation with reduced recontamination and waste.
Implementation Method 1
In the extended position, a main section of the highly magnetic portion of the shaft is directly exposed to the material flow such that in the extended position, the portion of the outer surface of the or each of the magnetic shafts directly exposed to the material flow magnetically attracts magnetic material interspersed within the material flow
Data Source
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AI summary
A magnetic separation apparatus (10) for separating magnetic materials from non-magnetic materials in a material flow comprising self cleaning magnetic separators (15) comprising: a cylinder (20) having a first end closer to a material flow than its second end in use, a piston (25) slidingly mounted within the cylinder (20), and a magnetic shaft (30) extending from the piston (25), the piston (25) and cylinder (20) adapted to move the magnetic shaft (30) between an extended position (31) and a retracted position (32), such that in the extended position (32), at least a sleeveless portion of an outer surface of the magnetic shaft (30) is exposed to the material flow and in the retracted position the magnetic portion is retracted substantially or wholly within the cylinder (20), the apparatus including a protected shaft wiper (120) and shaft seal (125) within the first end of the cylinder (20) for removing extracted magnetics.