Stone Separator Air Flow Design for Material Separation
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Solution Overview
Problem
Existing stone separators face challenges in effectively separating stones and inert substances from lighter materials like films or foils, as these lightweight components can be difficult to suck off or are not well-separated due to their fluid-dynamic behavior, leading to inefficient separation and potential re-mixing with heavier materials.
Innovation Solution
A device with a chamber and conveyor belts, utilizing a pressure fan to create an air flow and multiple separation areas with fluid guide plates and negative pressure zones, allows for the separation of different material groups based on fluid resistance, ensuring stones and inert substances are separated from lighter materials, with the use of adjustable separating vertices and multiple conveyor belts to facilitate targeted air flow and minimize turbulence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a suction device is used to separate lightweight materials from stones, then lightweight materials can be removed, but stones may settle on light substances and interfere with further separation
Solution Approach 1:
The separation process is divided into multiple sequential stages: first separation area for initial light material removal, calming zone for flow stabilization, and second separation area for complete light material extraction. This segmented approach prevents stones from interfering with subsequent separation stages while ensuring complete removal of lightweight materials.
Solution Approach 2:
The first separation area performs preliminary removal of light materials before the material flow enters the calming zone and second separation area. This preliminary action prevents stones from settling on light substances that would otherwise interfere with complete separation in later stages.
2Productivity
If air flow is increased to improve separation of light materials, then extraction efficiency improves, but turbulence increases causing light materials to flow back into stone fraction
Solution Approach 1:
The calming zone acts as an intermediary region between the first and second separation areas. It stabilizes the air flow and reduces turbulence generated by the pressure fan before material enters the second separation area, preventing light materials from being thrown back into the stone fraction while maintaining effective extraction.
Solution Approach 2:
Different regions of the device have different air flow characteristics optimized for their specific function: the first separation area has strong upward air flow for initial separation, the calming zone has reduced and stabilized flow to minimize turbulence, and the second separation area has controlled negative pressure for complete light material extraction.
3Manufacturing precision
If multiple separation areas are added to improve separation quality, then separation completeness improves, but device complexity increases
Solution Approach 1:
Multiple separation functions are combined into a single integrated device structure. The first separation area, calming zone, and second separation area are arranged sequentially within one device, sharing common structural elements like the housing and conveyor belt system, thereby achieving high separation quality without proportionally increasing device complexity.
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 approach enables efficient separation of multiple material groups with minimal effort, preventing lighter materials from re-mixing with heavier components and improving the extraction of lighter materials by using targeted air flow and negative pressure areas, resulting in a more effective and efficient separation process.
Implementation Method 1
a first material group such as stones and/or inert materials and/or heavy parts with the lowest fluid resistance of all material groups of the material mixture
Implementation Method 2
a second material group can be at least partially separated by means of the first negative pressure area in a horizontal lateral direction from a main direction of the material flow
Data Source
Figure 1
Figure 2
AI summary
A device for processing a material mixture, with a first conveyor belt which is connected to a chamber, has at least one pressure blower provided in the internal space of the chamber for generating an airflow aimed from below at the material mixture falling into the chamber. At least two collectors are arranged offset along the chamber floor at different distances to the entry point of the material mixture which faces the chamber. These collectors are delimited from one another in terms of surface area by at least one separating crest, which is movably arranged on the chamber floor and extends from the chamber floor in the direction of the chamber upper side. A first material group, such as stones and/or inert materials and/or heavy parts, with the lowest fluid resistance of all material groups of the material mixture, is separable at least to some extent from the material flow in a first separation region, in which a fluid flow and a material mixture flow through the device. In a second separation region with a settling zone and a first negative pressure region, a second material group is separable, at least to some extent.