Spiral Conveyor Dual-Filter Unit for Aluminum Chip Clogging

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Solution Overview

Problem

Conventional spiral conveyors face clogging issues with lightweight aluminum chips or scrapes, and existing filters are not easily retrofittable to existing conveyors.

Innovation Solution

A dual-filter system comprising a primary perforated metal filter and a secondary rotating mesh filter, with a washing nozzle to spray liquid for rotating the secondary filter, ensuring chips or scrapes are conveyed smoothly without clogging.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional filter is used in the spiral conveyor, then chip separation is achieved, but clogging occurs with lightweight aluminum chips

Engineering Contradiction:

Improvefilter performanceVSAvoidclogging

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The filter system is segmented into multiple components: a primary filter for initial separation and a secondary filter for fine filtration. This segmentation allows each filter to handle specific chip sizes and types, preventing overload and clogging of any single filter element.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The secondary filter is designed to rotate dynamically rather than remain stationary. This rotation prevents chip accumulation and clogging by continuously changing the filtration surface, allowing lightweight aluminum chips to be effectively separated without blocking the filter.

Inventive Principle:

Principle #15Dynamics

2Object-affected harmful factors

If a dual-filter system with rotation mechanism is implemented, then clogging is prevented, but device complexity increases

Engineering Contradiction:

Improveclogging preventionVSAvoidfilter unit structure

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The rotation of the secondary filter is achieved through self-service mechanism where cutting fluid pressure automatically drives the rotation. The system uses the existing cutting fluid flow to power the filter rotation, eliminating the need for external motors or complex drive mechanisms.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The cutting fluid hydraulic flow is utilized to rotate the secondary filter. The pressurized cutting fluid passes through channels that create rotational motion, using hydraulic principles to simplify the mechanical complexity of the rotation mechanism.

Inventive Principle:

Principle #29Pneumatics and hydraulics

3Object-affected harmful factors

If existing spiral conveyor is modified with filter unit, then clogging is prevented, but manufacturing cost increases

Engineering Contradiction:

Improveclogging preventionVSAvoidretrofit cost

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The filter unit is designed with universal applicability to fit various spiral conveyor models. Standardized components and adaptable mounting mechanisms allow the same filter unit design to be retrofitted across different conveyor sizes and configurations, reducing manufacturing costs through economies of scale.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The filter unit incorporates adjustable parameters such as filter mesh sizes, rotation speed control, and mounting positions that can be customized without changing the fundamental design. This allows cost-effective adaptation to different application requirements while maintaining the core clogging prevention functionality.

Inventive Principle:

Principle #35Parameter changes

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 dual-filter system effectively separates and conveys chips of varying sizes without clogging, using readily available and cost-effective materials, and can be retrofitted to existing conveyors.

Implementation Method 1

a washing nozzle for spraying washing liquid onto the secondary filter

Methodology Applied

Scientific EffectFluid spray: Fluid Spray

Implementation Method 2

a primary filter fixed at position close to an outer periphery of the conveyance spiral

Methodology Applied

Scientific EffectPhysical filtration: Filter (physical)

Implementation Method 3

a secondary filter rotating on the outside of the conveyance spiral and the primary filter

Methodology Applied

Scientific EffectMesh filtration: Filter (physical)

Data Source

PatentUS12390897B2Spiral conveyor and filter unit

Publication Date: 2025.08.19 TOKYO SEIMITSU HATSUJO

AI summary

A filter unit is connected between a tray and a discharging duct of a spiral conveyor. The filter unit includes a first filter (perforated metal) that is fixed at a position close to the outer periphery of a conveying spiral, and a second filter (mesh filter) that rotates on the outside of the conveying spiral and the first filter. A washing nozzle sprays a washing liquid on the second filter. The chips captured by the first filter are scraped by the rotating conveying spiral and delivered back to the conveying path and the chips passing through the first filter but captured by the second filter are removed by the washing nozzle and delivered back to the conveying path. The washing liquid is sprayed at a predetermined angle from the washing nozzle and collides with vanes arranged on the outer periphery of the second filter and provides rotational force on the second filter.