Wet Abrasive Recycling Feed for Consistent Waterjet Cutting
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Solution Overview
Problem
Existing abrasive waterjet cutting systems face challenges in efficiently recycling wet abrasive, as moisture content affects feeding and metering, leading to clogs and reduced cutting power, while traditional drying methods increase costs and energy consumption.
Innovation Solution
A system that integrates separate feed containers for dry and wet abrasive, with controlled metering and mixing in a cutting head to form an abrasive fluid jet, utilizing a metering device and dewatering techniques to manage moisture levels and ensure consistent flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by stationary object
If wet abrasive is recycled without drying, then energy consumption and costs are reduced, but feeding and metering become unreliable causing clogs
Solution Approach 1:
The system divides the abrasive feed system into separate containers: a first container for dry abrasive and a second container for wet abrasive. This segmentation allows each type of abrasive to be fed independently through dedicated pathways, preventing clogs in the dry abrasive feed system while enabling energy-efficient recycling of wet abrasive without requiring drying.
Solution Approach 2:
The system introduces an intermediary mixing chamber where dry and wet abrasive are combined before entering the cutting head. This intermediary zone allows the wet abrasive to be integrated with dry abrasive in controlled proportions, maintaining feeding reliability while preserving the energy benefits of recycling wet abrasive without complete drying.
2Use of energy by stationary object
If wet abrasive is recycled without drying, then costs and energy consumption are reduced, but cutting power is reduced
Solution Approach 1:
The system dynamically adjusts the ratio of wet to dry abrasive in the mixing chamber based on operational requirements. By controlling the parameters of abrasive composition, the system maintains optimal cutting power while preserving the energy efficiency of recycling wet abrasive, allowing flexible optimization of performance versus energy consumption.
Solution Approach 2:
Instead of completely drying the recycled abrasive (excessive action), the system uses partial drying or controlled moisture levels. This partial action approach recovers the energy benefits of recycling while maintaining sufficient abrasive effectiveness for cutting operations.
3Reliability
If traditional drying methods are used, then feeding reliability is improved, but costs and energy consumption increase
Solution Approach 1:
The system accepts that some wet abrasive will be lost or require minimal processing rather than investing in expensive and energy-intensive drying infrastructure. By using separate feed containers and controlled mixing, the system minimizes the need for complete drying while maintaining sufficient feeding reliability.
Solution Approach 2:
The system uses the wet abrasive itself as a component of the cutting fluid, allowing it to serve a functional purpose without requiring complete drying. The wet abrasive contributes to the cutting process while its moisture is managed through the separate feeding and mixing mechanisms, eliminating the need for energy-intensive drying operations.
4Reliability
If separate feed containers are used for dry and wet abrasive, then feeding reliability is improved, but device complexity increases
Solution Approach 1:
The separate feed containers serve multiple functions: they store different types of abrasive, control their individual flow rates, and prevent cross-contamination. The mixing chamber also serves multiple purposes by combining abrasives, controlling mixture ratios, and ensuring uniform distribution. This multi-functionality approach manages system complexity through purposeful design.
Solution Approach 2:
The system incorporates adjustable flow control mechanisms that allow dynamic regulation of dry and wet abrasive feed rates. This dynamic capability enables the system to adapt to different cutting conditions while maintaining feeding reliability, managing complexity through flexible control rather than fixed rigid structures.
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
Enables reliable and efficient recycling of wet abrasive, reducing costs and energy consumption by maintaining consistent abrasive flow and cutting power, while simplifying the recycling process.
Implementation Method 1
The dewatering device includes one or more ports that are fluidly coupled to both a vacuum and the lumen; providing suction to the wet abrasive through the one or more ports removes water from the wet abrasive
Implementation Method 2
Rotation of the auger transports portions of the wet abrasive that are positioned between adjacent flights of the auger along a length of the lumen
Implementation Method 3
generating a fluid jet within the abrasive fluid jet cutting head such that the fluid jet passes through the mixing chamber, entraining both the dry abrasive and the wet abrasive that has been fed into the mixing chamber into the fluid jet
Data Source
AI summary
Disclosed herein are components, systems, and methods of operating an abrasive fluid jet system that recycles and reuses abrasive particles. The systems and methods described enable accurate metering and consistent feeding of wet abrasive particles thereby reducing the time and cost of operations associated with drying the recycled abrasive particles prior to reuse. The system may adjust a ratio of wet abrasive to dry abrasive being provided to a cutting head to form an abrasive fluid jet. Components of the system may overcome challenges associated with clumping and other issues that result in difficulty metering wet abrasive.