Conveying Line Valve Assembly for Automatic Pig Cleaning
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Solution Overview
Problem
Existing construction machines face challenges in efficiently and automatically cleaning high-density material conveying lines, particularly those conveying materials like mortar, cement, or concrete, which are prone to manual cleaning errors and time-consuming processes.
Innovation Solution
A valve device with an actuating body and transmission device that allows for automatic switching positions, enabling the integration and transmission of media separation devices (pigs) to clean the conveying lines, separating and removing materials without manual intervention, using a drive mechanism and piston system for fluid-tight sealing and pressure control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual cleaning operations are used for high-density material conveying lines, then operational flexibility is maintained, but cleaning efficiency decreases and operator errors occur
Solution Approach 1:
The system enables self-service cleaning by automatically loading media separation devices into the conveying line through the valve device, eliminating the need for manual intervention. The valve device autonomously switches between conveying and cleaning modes, and the media separation device self-propels through the line using pressure gradients.
Solution Approach 2:
Manual mechanical cleaning operations are replaced by an automated system combining a valve device with switching positions and media separation devices. The mechanical action of manually inserting cleaning devices is substituted by automated valve actuation and pressure-driven device transmission.
2Loss of time
If manual cleaning operations are used, then adaptability to different cleaning needs is maintained, but time consumption increases
Solution Approach 1:
The valve device is pre-configured with multiple switching positions (first position for conveying, second position for cleaning) that can be activated in advance. Media separation devices are prepared in advance and automatically transmitted when the valve switches to the second position, eliminating on-site manual preparation time.
Solution Approach 2:
The system changes operational parameters by switching the valve between different positions to transition between conveying and cleaning modes. Pressure gradients are dynamically adjusted to propel media separation devices through the conveying line, optimizing cleaning speed without manual intervention.
3Reliability
If media separation devices are manually loaded into conveying lines, then precise positioning can be achieved, but operator safety is compromised
Solution Approach 1:
The valve device serves as an intermediary mechanism between the operator and the media separation device. Instead of operators directly handling devices in the conveying line, the valve device automatically transmits devices through sealed connections, eliminating direct human exposure to hazardous high-density material environments.
Solution Approach 2:
The hazardous function of manually loading media separation devices is extracted from the operator's tasks and assigned to the automated valve device. The valve device independently handles the transmission and positioning of cleaning devices, removing operators from safety-risk situations.
4Productivity
If the conveying line is continuously operated without cleaning interruptions, then productivity is maintained, but material buildup occurs
Solution Approach 1:
The system implements periodic cleaning cycles by automatically switching the valve to the second position at predetermined intervals or when buildup is detected. Media separation devices are periodically transmitted through the conveying line to clear accumulated material, then the valve returns to the first position to resume conveying operations, maintaining long-term efficiency.
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
Facilitates automatic, error-free cleaning of high-density material conveying lines by eliminating manual operations, ensuring efficient and reliable removal of materials through pressure gradients and fluid-tight sealing, thus enhancing operational safety and efficiency.
Implementation Method 1
In a second piston position, the piston is received in the connection such that this connection is separated from the receiving space in a fluid-tight manner by the piston
Implementation Method 2
whereby a pressure gradient acting on the media separation device is generated in order to move the media separation device along the pressure gradient through the thick matter conveying line
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to a valve assembly (1) for attachment to a viscous material conveying line (103) of a construction machine (100) for conveying viscous material (D), wherein the valve assembly (1) comprises: a base body (2) and an actuating element (3) adjustable relative to the base body (2) between a first switching position (P1) and a second switching position (P2), and an automatic transmission device (4, 4a) with a receiving chamber (5) for receiving a media separation device (M, M1), wherein the base body (2) has a first connection (K1) for connection to a pump side (101) of the construction machine (100) and a second connection (K2), wherein the actuating element (3) has a third connection (K3) for connecting the viscous material conveying line (103) of the construction machine (100), wherein the second connection (K2) and the receiving chamber (5) are connected to each other.wherein in the first switching position (P1) the first terminal (K1) and the third terminal (K3) are connected to each other for a flow of at least thick substance (D) between the first terminal (K1) and the third terminal (K3), wherein in the second switching position (P2) the second terminal (K2) and the third terminal (K3) are connected to each other for an automatic transmission of the media separation device (M, M1) between the third terminal (K3) and the transmission device (4, 4a).