Horizontal Shredder Discharge Grate Dynamics
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Solution Overview
Problem
Existing shredding machines require significant downtimes and conversion efforts to adapt to different comminution requirements, leading to inefficiencies in material processing and inability to produce high-quality metallic coolants like chilled scrap, as they are optimized for specific comminution tasks and lack flexibility in material outlet management.
Innovation Solution
A horizontal shredder system with a cylindrical hammer mechanism and a fixed bottom grate, equipped with a covering device that can be selectively opened or closed without stopping the rotor, allowing for continuous operation and improved material ejection quality by maintaining a consistent distance between hammers and grate, and additional independent pivotable grate covers for adjustable material outlet management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the discharge grate is replaced or adjusted to change particle size, then the material properties can be optimized, but significant downtimes and conversion efforts are required
Solution Approach 1:
The discharge grate is made movable instead of fixed, allowing it to be adjusted to different positions during operation. The grate can be tilted relative to the horizontal plane, enabling dynamic control of the opening cross-section and particle size without requiring grate replacement or machine shutdown.
Solution Approach 2:
The position and angle of the discharge grate are changed as controllable parameters. By adjusting the grate's position along the cylindrical housing and its tilt angle, the opening cross-section area is varied, thereby controlling the particle size of the comminuted material without physical replacement of components.
2Adaptability or versatility
If the rotor direction is reversed to switch between shredding and separation modes, then universal functionality is achieved, but considerable time is lost due to rotor inertia
Solution Approach 1:
The discharge system is segmented into multiple independent outlets: a first material outlet with a movable discharge grate for shredding mode, and a second material outlet with a discharge flap for separation mode. This allows selective use of different outlets for different processing modes without reversing the rotor direction.
Solution Approach 2:
The single rotor serves both shredding and separation functions by directing material to different outlets based on the processing mode. The rotor's rotation direction remains constant, but the functional mode is changed by selecting which outlet to use and how the discharge components are positioned.
3Manufacturing precision
If the bottom grate is pivotally mounted for adjustment, then particle size control is improved, but the heavy grate requires high energy expenditure and complex adjustment mechanisms
Solution Approach 1:
A hydraulic adjustment mechanism is used to move the discharge grate along the cylindrical housing and to tilt it. The hydraulic system provides the necessary force to move the heavy grate with relatively low energy expenditure compared to mechanical screw or lever mechanisms, while maintaining precise position control.
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A comminution machine (1) of the type of a horizontal shredder plant is described, comprising a stationary base frame (2) and side walls (3) for the rotatable mounting of a horizontally arranged axis of rotation (4) of a cylindrical hammer mill (12), at least one feed for comminution (5) on the downward rotating (6) side of the hammer mill (12) and at least one discharge area (7) downstream of the feed for comminution (5) in the direction of rotation (6) of the hammer mill (12), the discharge area being provided with a discharge grate (9) adapted to the cylindrical shape of the hammer mill (12) and fixedly resting on a frame (8) in the base frame, wherein at least one cover device (10, 10') is provided for selectively closing or opening part or all of the discharge area (7) provided with the discharge grate (9).