Woven Wire Screening Differential Crimping Throughput
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Solution Overview
Problem
Conventional woven wire screens have limited efficiency due to restricted throughput, which hinders the classification of materials effectively in shaker or vibrating screen apparatus.
Innovation Solution
The development of woven wire screenings with crimped warp and weft wires creating a knuckle height differential, along with additional straight or crimped wires, to enhance the tumbling action and increase throughput by ensuring all openings have substantially the same size, thereby improving material classification efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional woven wire screens are used with standard crimping, then the structure is simple and easy to manufacture, but the throughput is limited and efficiency is low
Solution Approach 1:
The patent applies local quality by differentiating the crimp depths of warp and weft wires. Specifically, the warp wires are crimped to a first depth while the weft wires are crimped to a second depth greater than the first, creating localized variations in knuckle height. This non-uniform local structure generates enhanced tumbling action of material on the screen surface, thereby increasing throughput without requiring complete structural redesign.
Solution Approach 2:
The invention implements asymmetry by creating an irregular upper screening surface through differential crimping. The asymmetric arrangement of knuckle heights (with weft knuckles higher than warp knuckles) disrupts uniform material flow and promotes tumbling motion. This asymmetric geometry transforms the otherwise flat, symmetric screen surface into a dynamic structure that enhances material classification efficiency.
2Productivity
If uniform crimp depth is used for all wires, then manufacturing is simple and consistent, but tumbling action is insufficient and throughput is limited
Solution Approach 1:
The patent resolves this contradiction by applying local quality through selective crimping. The warp wires are crimped to a first depth while adjacent weft wires are crimped to a greater second depth. This localized differentiation creates the desired tumbling effect while maintaining manufacturing feasibility, as the differential crimping can be achieved through standard wire forming processes applied to alternating wire sets.
3Productivity
If knuckle height differential is created between warp and weft wires, then tumbling action is enhanced and throughput increases, but the wire configuration becomes more complex
Solution Approach 1:
The patent addresses this contradiction by implementing local quality through differential crimping of specific wire sets. By crimping warp wires to a first depth and weft wires to a greater second depth, the invention creates localized height variations that enhance tumbling action. This approach achieves improved throughput through targeted local modifications rather than complex overall restructuring.
Solution Approach 2:
The invention applies parameter changes by modifying the crimp depth parameter of the wires. Specifically, it changes the crimp depth from a uniform value to two distinct values (first crimp depth for warp wires, second greater crimp depth for weft wires). This parameter differentiation creates the knuckle height differential that enhances material tumbling while maintaining relatively simple wire construction methods.
Data Source
AI summary
A woven wire screening for use in classifying material flowing therethrough and a method of forming the same. The woven wire screening includes a plurality of warp wires and a plurality of weft wires. The plurality of warp wires and the plurality of weft wires are interwoven to form an integral wire cloth having a plurality of openings for permitting material to be classified to flow through the openings. The integral wire cloth includes an upper screening surface configured to enhance the tumbling action of product impacting the upper screening surface to improve throughput of the woven wire screening.