Throwing Roller Separation of Light Flaky Cut Rolled Stems
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Solution Overview
Problem
The 'thin-roll and thin-cut' process for tobacco processing results in light flaky cut rolled stems (CRSs) with low density, leading to breakage, uneven blending, and quality control issues, as they are easily distributed on both sides of the blending belt, affecting the physical quality and de-dusting load of cigarettes.
Innovation Solution
A device and method using a throwing roller with a triangular prism guide plate and arc-shaped distribution plate, featuring adjustable angles and suction speeds, to separate light flaky CRSs by guiding them onto a concave arc surface, creating a fluidized separation space and utilizing negative pressure to remove light flaky components while maintaining the integrity of finished CRSs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the 'thin-roll and thin-cut' process is used to produce CRSs, then the filling value and cost-effectiveness are improved, but the uniformity of CRSs decreases and light flaky CRSs are generated
Solution Approach 1:
The patent extracts and removes light flaky CRSs from the mixed CRS material stream using a combination of airflow and mechanical throwing action. The throwing roller selectively ejects light flaky particles while retaining normal density CRSs, effectively separating the unwanted fraction from the desired material.
Solution Approach 2:
The patent changes the physical state and motion parameters of CRSs by controlling the throwing roller's rotation speed and the airflow velocity. By adjusting these parameters, the system optimizes the separation between light flaky CRSs and normal CRSs based on their density differences, achieving both high filling value and uniformity.
2Quantity of substance
If light flaky CRSs are present in the blend, then the cost is reduced, but the blending uniformity decreases and physical quality fluctuates
Solution Approach 1:
The patent applies preliminary action by removing light flaky CRSs before the blending process. The throwing roller and airflow system pre-separate the material stream, ensuring that only uniform-density CRSs enter the blending stage, thereby guaranteeing consistent blending uniformity and physical quality in the final product.
Solution Approach 2:
The patent introduces airflow as an intermediary medium between the CRS material stream and the throwing roller. The controlled airflow lifts and positions light flaky CRSs for selective removal, enabling precise separation that maintains blending uniformity while managing material costs.
3Productivity
If light flaky CRSs are not removed, then the processing load is reduced, but the de-dusting load increases and quality control becomes difficult
Solution Approach 1:
The patent converts the harmful low-density property of light flaky CRSs into a beneficial separation mechanism. By utilizing the density difference between light flaky and normal CRSs, the throwing roller system selectively removes the problematic fraction, reducing de-dusting load downstream while maintaining processing efficiency.
Solution Approach 2:
The patent employs pneumatic principles by using controlled airflow to interact with the CRS material stream. The airflow selectively suspends and transports light flaky CRSs to the throwing roller for removal, efficiently reducing de-dusting load without significantly increasing overall processing complexity.
4Stability of the object's composition
If a separation device is introduced to remove light flaky CRSs, then the blending uniformity is improved, but the device complexity increases
Solution Approach 1:
The patent merges the separation function with the existing CRS handling system. The throwing roller is integrated into the material conveyance path, combining separation, conveying, and removal functions in a single compact unit, thereby improving blending uniformity without proportionally increasing device complexity.
Solution Approach 2:
The patent implements a simple discard mechanism for light flaky CRSs that are separated by the throwing roller. The removed material is diverted from the main process stream in a straightforward manner, avoiding complex recovery systems while maintaining high blending uniformity in the retained CRSs.
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 solution achieves high whole cut rates, improved processing endurance, uniform blending, and desired color of finished CRSs, reducing breakage and moisture loss, while allowing for efficient separation and integration into the production line without disrupting material conveyance.
Implementation Method 1
a suction port T2 is provided above the CRS distribution plate 2, and is connected to an external suction fan T22
Implementation Method 2
allowing light flaky CRSs to be sucked into the suction port T2
Implementation Method 3
forming a fluidized separation space above the concave arc surface of the distribution plate 2
Implementation Method 4
rotating the throwing roller 12 with the tip 1211 facing forward, such that the CRSs between the homogenizing baffles 121 are dispersed axially, and are thrown into the concave arc surface of the CRS distribution plate 2
Implementation Method 5
allowing remaining finished CRSs to fall to the guide plate 3 by gravity and to be discharged from the discharge port T3
Data Source
AI summary
A device for separating light flaky cut rolled stems (CRSs) by a throwing roller is provided. The device includes a vertically provided separation bin, and a CRS guide device and a CRS distribution plate which are arranged in the separation bin. The present disclosure further provides a method for separating light flaky CRSs by using the device. The present disclosure achieves full separation of finished CRSs from light flaky CRSs. The device of the present disclosure is designed for the first time, and can be directly connected to a pneumatic CRS feeding and discharging section of a production line. The device of the present disclosure is compact and suitable for industrial production.