Sensorized Spacer for High-Pressure Mixing Head
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Solution Overview
Problem
Existing high-pressure mixing heads for reaction molding face issues with friction and wear due to resin film accumulation, leading to thermal increases, deformations, and maintenance challenges, including the need for reliable force measurement and frequent cleaning to prevent resin accumulation and damage.
Innovation Solution
A sensorized spacer with deformation detection sensors, such as extensometers, is integrated between the self-cleaning stem and supply duct to accurately measure forces and monitor deformations, allowing for optimal performance monitoring and maintenance, while being designed for easy replacement and lubrication without interfering with force measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the self-cleaning stem is made with a larger diameter for mechanical robustness, then strength is improved, but friction and wear increase due to resin film accumulation on the sliding surfaces
Solution Approach 1:
A spacer element is introduced as an intermediary component between the self-cleaning stem and the supply duct. This spacer serves as a mediator that collects resin accumulations away from the sliding surfaces of the self-cleaning stem, thereby reducing direct contact between the resin film and the stem surfaces, which reduces friction and wear while allowing the stem to maintain its robust structure
Solution Approach 2:
The harmful resin film accumulations are extracted or removed from the critical sliding surfaces of the self-cleaning stem by the spacer. The spacer creates a dedicated space where resin can accumulate without affecting the stem's movement, effectively separating the resin accumulation function from the stem's sliding function
2Measurement precision
If deformation detection sensors are applied on the external surface of the spacer, then measurement precision is improved, but the sensors are vulnerable to damage from resin accumulations and cleaning operations
Solution Approach 1:
The deformation detection sensors are nested inside cavities within the spacer structure. This nesting protects the sensors from external damage during cleaning operations and resin accumulation, while the cavities are positioned and dimensioned to allow the sensors to still detect deformations of the spacer effectively
Solution Approach 2:
The cavity walls act as an intermediary layer between the sensors and the harsh external environment (resin accumulations and cleaning tools). This intermediary structure transmits the mechanical deformations to the sensors while protecting them from direct contact with harmful elements
3Device complexity
If the spacer is designed as a single integral piece, then device complexity is reduced, but ease of repair and maintenance deteriorates due to inability to access internal components
Solution Approach 1:
The spacer is segmented into multiple components: the main spacer body, removable closing flanges, and internal cavity structures. This segmentation allows the closing flanges to be removed for maintenance access to internal components like sensors and lubrication systems, while the main spacer body remains as a robust structural element
Solution Approach 2:
The closing flanges serve multiple functions: they close the cavities during operation, provide access points for maintenance when removed, and allow lubrication to be introduced into the spacer's internal channels. This multi-functionality reduces the need for separate maintenance access structures
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 sensorized spacer effectively measures forces and deformations, enabling timely maintenance and preventing resin accumulation, thus reducing wear and ensuring continuous optimal performance of the mixing head by detecting operational conditions and facilitating quick and effective maintenance.
Implementation Method 1
at least one deformation detection sensor applied at at least one available deformation surface of the at least one upright and adapted to detect longitudinal and/or transversal deformations of the at least one upright
Data Source
AI summary
The present invention relates to a spacer for high pressure mixing head comprising a control cylinder flange, a head body flange, and a plurality of uprights adapted to interconnect the control cylinder flange and the head body flange. At least one of the plurality of uprights comprises at least one deformation detection sensor applied at at least one available deformation surface thereof and adapted to detect longitudinal deformations and/or transversal deformations of the at least one of the plurality of uprights. The present invention also relates to a related mixing and dosing head and to a related apparatus.