Ultrasound Detection for Screening Module Detachment
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Solution Overview
Problem
Modern screening devices face challenges in maintaining a large active surface with high stability while allowing for easy exchange of individual screening modules, as existing methods risk detachment during operation, which can compromise product quality and lead to equipment breakdowns.
Innovation Solution
A detection system using ultrasound sensors positioned near the discharge of the screening deck to detect foreign objects, such as detached screening modules or liner elements, by monitoring the mass flow and applying threshold values to differentiate between sorted material and foreign objects, allowing for timely re-attachment and preventing operational disruptions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If the entire screening surface is made of a single screening module to maximize active surface, then the active surface area is maximized, but the operating expenses increase significantly due to the need to exchange the entire screen deck for local wear
Solution Approach 1:
The screening surface is divided into multiple interchangeable screening modules that can be independently replaced. This allows the active surface area to be maximized while enabling cost-effective maintenance, as only the worn modules need replacement rather than the entire screen deck.
2Area of moving object
If the number of supporting points is reduced to minimize dead surface, then the active surface area increases, but the stability and rigidity of the screening module decrease
Solution Approach 1:
The screening modules are designed with optimized supporting point distributions that provide sufficient stability where needed while maintaining maximum active surface area. The support structure is strategically positioned to ensure rigidity without creating excessive dead surface.
3Stability of the object's composition
If conventional locking methods are used to secure screening modules, then the modules are locked in place, but there is always a risk of detachment during use which can compromise product quality and cause equipment breakdown
Solution Approach 1:
A detection system with sensors is implemented to continuously monitor the screening modules and provide feedback on their status. This allows for real-time detection of detached or loose modules, enabling timely intervention to prevent product quality compromise and equipment breakdown.
Solution Approach 2:
The conventional mechanical locking and detection methods are replaced with an ultrasound-based detection system. The ultrasound sensors detect changes in acoustic properties caused by detached or loose modules, providing a more reliable and non-contact monitoring method that reduces the risk of detachment-related failures.
4Reliability
If a detection system is implemented to monitor detached modules, then the reliability improves, but the device complexity increases
Solution Approach 1:
Complex mechanical detection systems are replaced with an ultrasound-based detection system that uses acoustic waves to sense changes in the screening module status. This provides reliable detection capability while maintaining relatively simple system architecture, as the ultrasound sensors can detect both detached modules and liner element issues through acoustic property 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 system effectively monitors and prevents the detachment of screening modules and liner elements, ensuring continuous operation and maintaining product quality by stopping the screening device when foreign objects are detected, thus reducing maintenance costs and preventing downstream issues.
Implementation Method 1
the sensor comprises an ultrasound sensor
Data Source
AI summary
The invention relates to a detection system in a screening device for screening material, e.g. aggregate, ore or similar, comprising at least one screening decks, the at least one screening deck having a screening surface comprising one or more screening modules. The system comprises a sensor arranged at or near at least one screening deck of the screening device. The sensor is arranged such that it can detect objects present leaving the at least one screening deck. The invention also relates to a method for detection of objects in a screening device, and use of the detection system.