Suction cleaner
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Solution Overview
Problem
Existing cyclonic separators in suction cleaners face challenges in securely attaching filters to the shroud structure due to the small contact surface area, leading to potential detachment and reduced efficiency in dirt separation.
Innovation Solution
The introduction of a recessed channel on the shroud struts allows for a greater adhesive contact area, securely attaching a screen or mesh filter, and a multi-stage cyclonic separator assembly with parallel second cyclone separators and a sealing plate configuration to enhance dirt separation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a filter is attached to the shroud structure with limited contact surface area, then the device complexity is reduced, but the reliability of filter attachment deteriorates leading to potential detachment
Solution Approach 1:
The recessed channel extends in the axial direction of the shroud strut, transforming a two-dimensional surface attachment into a three-dimensional engagement. This allows the filter to be secured within the recessed channel rather than merely on the outer surface, significantly increasing the contact surface area and attachment reliability without adding complex external structures
2Productivity
If multiple second cyclone separators are arranged in parallel, then the productivity of dirt separation is improved, but the device complexity increases due to additional sealing plates and securing members
Solution Approach 1:
The separator assembly is divided into modular components: multiple second cyclone separators can be arranged in parallel, each with its own body extending through openings in the lower sealing plate. The upper and lower sealing plates act as common structural elements that secure multiple separators simultaneously, allowing scalable configuration based on productivity requirements
Solution Approach 2:
Multiple second cyclone separators are combined within a single separator assembly, sharing common upper and lower sealing plates and a unified intermediary chamber. The securing members integrate all components into a single assembly unit, achieving economies of scale and reducing overall system complexity despite increased separation capacity
3Reliability
If the filter contact area with shroud is increased using a recessed channel, then the filter attachment reliability is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The recessed channel is formed only on specific portions of the shroud struts where filter attachment is required, rather than modifying the entire shroud structure. This localized approach concentrates manufacturing precision requirements to specific critical areas while leaving other parts of the structure simpler to manufacture
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 configuration ensures a secure attachment of filters and improves dirt separation efficiency by maintaining the filter's position and enhancing the separation of both coarse and fine dirt particles, reducing re-entrainment and improving airflow path design for better suction performance.
Implementation Method 1
a first cyclone separator for separating coarse dirt from an air flow; a plurality of second cyclone separators arranged fluidly in parallel for separating fine dirt from an air flow
Implementation Method 2
a cyclonic separator supplies a high speed rotating airflow into a generally cylindrical chamber
Implementation Method 3
The introduction of a recessed channel on the shroud struts allows for a greater adhesive contact area, securely attaching a screen or mesh filter
Data Source
Figure 1
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Figure 3
AI summary
A separator assembly for removing dirt from an air flow in a suction cleaner, the separator assembly including: a first cyclone assembly including a first cyclone separator for separating coarse dirt from an air flow; and a second cyclone assembly including: a plurality of second cyclone separators arranged fluidly in parallel for separating fine dirt from an air flow, each providing a body with a cyclone inlet towards an upper end and a dirt outlet formed at a lower end; a lower sealing plate surrounding the lower ends of the second cyclone separators and configured such that the body of each second cyclone separator extends through a respective opening in the lower sealing plate, such that the dirt outlets of the second cyclone separators lie below the sealing plate, an upper sealing plate disposed adjacent the upper ends of the second cyclone separators, an intermediary chamber configured such that partially cleaned air is drawn into the intermediary chamber from the first cyclone assembly and subsequently into the inlets of the second cyclone separators, the upper end of the intermediary chamber being sealed by the upper sealing plate, and a securing member formed between and securable to each of the upper sealing plate and lower sealing plate.