RU2461416C2 - Velocity layer electromagnetic apparatus and method of its production - Google Patents

Abstract

FIELD: process engineering.

SUBSTANCE: set of inventions relates to mixers or mincers to be used in various industries. Proposed apparatus comprises reaction chamber from nonmagnetic material, set of ferromagnetic particles arranged inside reaction chamber, and inductor incorporated magnetic core made up of toroid composed by strip of coiled electric steel wound in spiral of Archimedes with turns glued by epoxy adhesive. Set of coils is fitted on toroid and connected with device control unit and either interconnected and connected with common power source with 50 Hz sine voltage, or connected to independent power supplies built around variable-frequency inverters via separate control units. Proposed method comprises making inductor from electric steel to shape to toroid, gluing its elements together by epoxy adhesive, and cutting sector shaped to reaction tube from said toroid. Inductor coils are pre-wound and arranged on inductor via cutout made in toroid. Said toroid is composed of strip of coiled electric steel wound in spiral of Archimedes.

EFFECT: higher efficiency.

2 cl, 15 dwg

Description

The group of inventions relates to the field of engineering, and more particularly to devices for mixing and / or grinding liquid and granular media, and can be used in various industries, agriculture and forestry, including the implementation of nanotechnology.

There are various designs of devices that use the energy of an alternating electromagnetic field to process materials, acting on ferromagnetic particles that directly interact with the processed material (see, for example, RF patents for utility models NN: 45648, 53933, 68355, 69415, for inventions NN: 48211 , 168264, 179283, 192755, 237309, 325988, 355833, 764717, 856533, 1101291, 1329809, 2049562; WIPO NN 2007/114731, WO 2009061236, UK patent N 2092464, and also devices according to the book: D. D. Logvinenko, O. Shelyakov .P. "Intensification of technological processes in devices with a vortex layer", Kiev, Technique, 1976, etc.).

All of the mentioned devices, although they provide mixing and grinding of liquid and granular media, however, they are difficult to manufacture and operate, which prevents their unification and, accordingly, increases their cost and reduces the convenience of working with them, which, in turn, significantly limits the scope of use of such devices.

Known, for example, is the electromagnetic apparatus of the vortex layer (hereinafter referred to as the EVAS) according to the book: Logvinenko DD, Shelyakov OP "Intensification of technological processes in devices with a vortex layer", Kiev, Technika, 1976, pp. 67-71, Fig. 57, 58, which contains: a reaction chamber of non-magnetic material to accommodate the processed liquid or granular media, a set of ferromagnetic particles (needles) placed in the cavity of the reaction chamber, and an inductor made in the form of a stator of an asynchronous electric motor having a yoke assembled from electrotechnical plates st ali, and a set of coils placed on it, connected to an electric power source and an EAFM operation control unit, as well as a device for feeding and unloading the processed material into the reaction chamber.

Such an apparatus, although it allows you to effectively mix or grind a wide variety of liquid and granular media, however,

firstly, due to a rather complicated design, it is not technologically advanced to manufacture and has a high cost price;

secondly, such an apparatus has low productivity, because in order to ensure the necessary values of the magnetic induction of the alternating electromagnetic field of the inductor in the reactive zone of the EMF within 0.1 ... 0.2 Tesla, one has to either increase the number of turns in the coils of the inductor, or increase the current in the coils , i.e. between these two parameters it is necessary to ensure the optimal ratio, minimizing active electrical losses in the coils. Nevertheless, as practice shows, Cos φ does not exceed 18% on the best samples of EVAF. The inductor coils overheat during the operation of such an EMF; therefore, they require additional heat removal. Conventional heat dissipation using an air fan is not enough, therefore, it is necessary to introduce a liquid heat dissipation using transformer oil, which significantly complicates the design of the EMF and increases its cost.

Increasing the performance of such an EMF with a typical design of an inductor assembled from a set of plates of stamped sheet electrical steel is very difficult, because:

- if you increase the throughput of the apparatus by increasing the diameter of the reaction tube, then the gap between the poles of the inductor will inevitably increase, which will lead to a sharp increase in active energy losses and increase in power consumption;

- if you reduce the gap between the poles of the inductor while increasing the length of the inductor, for example, by using the standard stator of a submersible submersible pump, this reduces the diameter of the reaction tube and, accordingly, decreases the performance of the EMF;

- if you increase the operating frequency of the supply current from 50 to 1000 Hz, use various "swirlers" of the flow of the processed materials, introduce various active and passive inserts into the axial zone of the reactor, where the magnetic field is most attenuated and the energy of the vortex is minimal, then the design of the EMF is significantly complicated, so is its manufacture and operation.

The closest solution in technical essence and the achieved result from its use to the claimed solution is the known electromagnetic vortex layer apparatus according to RF patent N 1329809, B01F 13/08, 1987 (intended for mixing molten metal in a workpiece exiting from a continuous casting plant), containing : a reaction chamber of non-magnetic material, a set of ferromagnetic particles placed in the cavity of the reaction chamber, and an inductor with C-shaped lined magnetic circuits assembled from plates of electric Technical steel and placed thereon coils connected to a source of electricity and the operation control unit EAVS.

In this design, the core of the magnetic circuit is assembled from a set of plates of sheet electrical steel, which makes such an apparatus expensive to manufacture and operate, significantly limiting its performance and the possibility of increasing it.

The task to which the invention is directed is to expand the arsenal of existing technical means of a certain purpose in this area by significantly increasing the efficiency of the electromagnetic apparatus of the vortex layer (EAVS) while improving manufacturability and reducing the cost of its manufacture, as well. reduce energy consumption during its operation.

This problem is solved primarily due to the technical result from the use of the claimed invention, which consists in simplifying the design of the EMF, improving the reliability of its operation and increasing its energy efficiency.

The specified technical result is achieved by the fact that in the known electromagnetic apparatus of the vortex layer containing a reaction chamber of non-magnetic material, a set of ferromagnetic particles placed in the cavity of the reaction chamber, and an inductor having at least one C-shaped magnetic circuit with a set coils connected to a power source and a control unit for the operation of EAF,

firstly, the magnetic circuit is made in the form of a toroid from a tape of rolled electrical steel wound along the "Archimedes spiral", while the turns of the tape are fastened together using a clamp made in the form of an adhesive, for example, epoxy glue;

secondly, the coils are interconnected in series and connected to a common power source with a sinusoidal voltage frequency of 50 Hz;

thirdly, to increase the performance of the ABC coils can be connected to individual power sources such as inverter converters with a variable frequency current from 1 to 2500 Hz through individual control units.

The proposed design of the EMF with the original toroidal design of the magnetic circuit can significantly increase the number of turns in the inductor of the EMF and at the same time supply the EMF with small currents. In addition, for cooling the EMF, you can limit yourself to an air fan.

There are various methods for the manufacture of electromagnetic devices containing inductors with magnetic circuits.

According to the accepted technology (see, for example, the book of Antonov MV and Gerasimova LS "Technology for the production of electrical machines", M., Energoizdat, 1982, p. 138 ... 208 "), the magnetic circuit of an electrical machine is assembled from plates of an electrical steel, electrically isolated from each other, pulling them together using a complex system of studs, grooves, pressed nuts, jumpers, dowels, etc. Plates are pre-cut from sheet or rolled electrical steel on a die cut, then removed from the cut plates dissolved burrs, and, in some cases, wafers are subjected to heat treatment for stress relief and oxidation.

This method, although it allows the manufacture of electromagnetic devices of the vortex layer of known designs, however, it is ineffective because it is very difficult to implement due to the large number of operations requiring large material, labor and energy costs.

The closest solution in technical essence and the achieved result from its use to the claimed solution is a well-known method of manufacturing an electromagnetic apparatus of the vortex layer (EAVS) according to the book: Logvinenko D.D., Shelyakov O.P. "Intensification of technological processes in devices with a vortex layer", Kiev, Technique, 1976, p. 71, which includes the following operations:

- manufacture of an inductor (consisting of yoke and poles) from varnish-insulated sheets of electrical (transformer) steel,

- the screed of the pole plates with insulated steel studs, and the yoke plates with two rings of non-magnetic steel, fastened together by the outer diameter of the yoke,

- fastening the poles to the yoke with special bolts,

- placement (winding, installation and alignment of the inductor coils) in the housing,

- connecting the coils to a power source,

- boring (cutting part) of the inductor,

- placement in the bore (in the cutout) of the inductor of the working chamber (reaction tube) with a replaceable sleeve made of stainless steel grade X18H10T or other non-magnetic material, for example, titanium.

This method, although it makes it possible to manufacture electromagnetic devices of the vortex layer of known designs, however, it is ineffective, since practice shows that the coefficient of metal utilization when cutting plates from a sheet of such a complex shape as for an EAF inductor does not exceed 0.5, t. e. almost half of the very expensive source electrical steel sheet is wasted.

In addition, during the assembly of the inductor package from the plates, it is very difficult to achieve a tight contact of the plates with each other, which leads to vibration of the plates and to a violation of the electrical insulation between the plates, and when the electrical conductivity between the plates is disturbed, the contact zones become very hot.

The process of winding, mounting and aligning the inductor coils in the housing is very complicated according to traditional technology (see, for example, the book by Antonov MV and Gerasimova LS "Technology for the production of electrical machines", M., Energoizdat, 1982, p. 208 ... 265 ").

The problem to which the invention is directed, is to significantly increase the efficiency of the functioning of the electromagnetic apparatus of the vortex layer (EAVS) while improving manufacturability and reducing the cost of its manufacture, as well as to reduce energy consumption during its operation.

This problem is solved primarily due to the technical result from the use of the claimed invention, which consists in simplifying the manufacturing and assembly technology of EVAF, reducing energy consumption during its manufacture and operation, as well as reducing labor costs while ensuring accuracy in the assembly of the apparatus.

The specified technical result is achieved by the fact that in the known method of manufacturing an electromagnetic apparatus of the vortex layer, including:

- manufacture of an inductor from electrical steel,

- fastening the elements of the inductor to each other,

- boring (cutting part) of the inductor,

- placement in the bore (in the cutout part) of the inductor of the reaction chamber,

- placement of inductor coils,

- connecting the coils to a power source,

firstly, the manufacture of the inductor is made of rolled electrical steel in the form of a toroidal magnetic circuit (toroid) by winding the tape along the "Archimedes spiral";

secondly, the fastening of the inductor elements (individual turns of the toroid) and their electrical isolation between themselves is carried out by applying a fixing hardener - epoxy glue to the tape during winding of the toroid;

thirdly, the bore (cutting out of the part) of the inductor is performed after the fixing hardener has hardened by cutting a separate sector (segment) from the toroid with a profile corresponding to the profile of the reaction chamber;

fourthly, the inductor coils are wound in advance and their placement on the inductor is done through a cut in the toroid.

The introduction of new operations and the special implementation of existing and new operations can significantly reduce both labor costs and manufacturing costs, as well as improve the quality and reliability of the EMF.

The proposed invention is illustrated by drawings, which depict the following:

- figure 1 shows a design variant of the electromagnetic apparatus of the vortex layer with one toroidal magnetic circuit with a cutout for a cylindrical reaction chamber;

- figure 2 shows a design variant of the electromagnetic apparatus of the vortex layer with one toroidal magnetic circuit with a cutout for a rectangular reaction chamber in section;

- figure 3 presents in isometric image of a design variant of the electromagnetic apparatus of the vortex layer with one toroidal magnetic circuit with a cutout for the reaction chamber with a cross section of arbitrary shape;

- figure 4 shows a top view of the design of the proposed electromagnetic apparatus of the vortex layer with one toroidal magnetic circuit with a cutout for the reaction chamber with a cross section of arbitrary shape;

- figure 5 shows a diagram of the assembly of the inductor with the movement of the coils through the cutout of the toroid, followed by the placement of these coils on the toroid;

- Fig.6 shows a front view of a design variant of the electromagnetic apparatus of the vortex layer with two toroidal magnetic cores;

- Fig.7 shows a top view of a design variant of the electromagnetic apparatus of the vortex layer with two toroidal magnetic cores;

- Fig. 8 is an isometric view of an embodiment of the design of the electromagnetic apparatus of the vortex layer with two toroidal magnetic circuits;

- Fig. 9 shows an isometric image of an embodiment of the design of the electromagnetic apparatus of the vortex layer with three toroidal magnetic circuits;

- figure 10 shows a front view of a design variant of the electromagnetic apparatus of the vortex layer with three toroidal magnetic cores;

- figure 11 shows a top view of a design variant of the electromagnetic apparatus of the vortex layer with three toroidal magnetic cores;

(In order not to overload the drawings, coils on some magnetic circuits are conditionally not shown);

- Fig. 12 shows a diagram of the electrical connection of the EAF coils with a common power source;

- Fig.13 shows a diagram of the electrical connection of the coils EVA with individual power supplies;

- Fig. 14 shows an isometric magnetic circuit in the form of an "Archimedes spiral";

- Fig.15 shows a top view of the magnetic circuit in the form of a "spiral of Archimedes."

The proposed electromagnetic device of the vortex layer (EAVS) (see Figure 1) contains a reaction chamber (pipe) 1 of non-magnetic material (for example, titanium), a set of ferromagnetic particles 2 (made, for example, in the form of needles from tool steel grade U7 ( or U8, or U10, or 9XC, or 5XH) according to GOST 1435-99, 5950 ... 2000, placed in the cavity of the reaction chamber 1 (for example, poured on a grid (not shown) in the working zone of the reaction chamber, and an inductor having at least one C-shaped magnetic core 3 with a set placed on it in advance of amotene coils 4 connected in the basic version (see Fig. 12) with a common source 5 of power supply and a unit 6 for controlling the operation of the EMF.

The magnetic core 3 is made in the form of a toroid made of electrical steel tape, for example, grade 20880 according to GOST 3836-83, wound along the "Archimedes spiral" (see Fig. 14, 15), and the turns of the tape are fastened together using a clamp (not shown shown), made in the form of an adhesive - epoxy adhesive brand EDP according to TU 2385-090-07510508-2008. The dimensions of the toroid 3 (outer and inner diameter, as well as its height), if necessary, can be several orders of magnitude larger than the diameter of the reaction chamber (pipe) 1.

Using toroidal magnetic cores 3 it is easy to assemble an EMF with one pair of poles (see Figure 1), with two pairs of poles (see Fig. 6, 7, 8), three pairs of poles (see Fig. 9, 10, 11) etc.

Moreover, the number of coils 4 on the toroidal magnetic circuit (toroid) 3, their sizes, cross-section and wire mark are limited by both the required capacity of the EMF, the specifics of the material being processed, and the dimensions of a particular toroid 3.

In the first (basic) embodiment of the EAFM (see Fig. 12), all coils 4 for adding magnetic fields arising in each coil are connected in series with each other and connected to a common power supply 5 (for example, with a three-phase industrial network with a sinusoidal voltage of 380 V, frequency of 50 Hz) and with a unit 6 for controlling the operation of the EMF.

To increase the performance of the EMAS, the coils 4 can be connected (see Fig. 13) to individual power sources 7 of the type of inverter converters with a variable frequency current from 1 to 2500 Hz through individual control units 8.

The proposed electromagnetic device of the vortex layer (EAF) is operated as follows.

First, a program for processing a specific material to the desired condition is introduced into the ECAW operation control unit 6 (or individual control units 8). Then, with the help of block 6 (or blocks 8), an EMF is turned on and the processed material (not shown) is fed into the reaction chamber (pipe) 1. After switching on the EMF, depending on the selected material processing program, the working fluids — ferromagnetic particles (needles) 2 in the reaction zone of the EMF depending on the specified program in block 6 (or in blocks 8) of the EMF operation control can be under the influence of three or more magnetic fields, different in magnitude, direction and frequency, and to make complex movements in the three-dimensional space of the reaction zone of the EVAF, which eliminates the so-called "dead zones" in the reaction zone of the EVAF, in which the material to be processed did not It is affected by the needles 2, which, in turn, guarantees the fulfillment of a given processing program and ensures the required quality of the processed material at a given AEMS productivity.

Using the proposed group of inventions allows:

1. Significantly increase the efficiency of the functioning of the electromagnetic apparatus of the vortex layer (EAVS) by expanding the range of its use, for example, by providing the possibility of obtaining ultrapure and finely dispersed substances necessary for the implementation of increasingly developing nanotechnologies.

2. To increase manufacturability and reduce the cost of manufacturing EVAF by simplifying its design, as well as by reducing energy consumption in its manufacture and by increasing the utilization of the source metal in the manufacture of magnetic core (s). (In the manufacture of the electromotive forces of the proposed design, the utilization of the source metal in the manufacture of the toroidal magnetic circuit is significantly increased (up to 0.9 or more) compared to the manufacture of a traditional magnetic circuit from stamped blanks in the form of plates of complex shape from sheet electrical steel).

3. Significantly reduce energy consumption during the operation of the EMF due to the possibility of selection and application of a more efficient power supply circuit of the inductor coils, the possibility of supplying the EMF with small currents and the possibility of cooling the EMF with an air fan.

4. To increase the reliability of the EMF by eliminating the "bounce" of the elements (plates) of the inductor and their overheating by ensuring the accuracy of assembly and reliable fixation of parts of the apparatus.

5. Improve the convenience of personnel in the manufacture of parts and assembly of the apparatus.

Claims (2)

1. The electromagnetic apparatus of the vortex layer, containing a reaction chamber of non-magnetic material, a set of ferromagnetic particles placed in the cavity of the reaction chamber, and an inductor having at least one C-shaped magnetic circuit with a set of coils placed on it, connected to a power source and control unit for the operation of the apparatus, characterized in that the magnetic circuit is made in the form of a toroid from a tape of rolled electrical steel wound along the "Archimedes spiral", the turns of the tape are fastened together by means of a fixed curing hardener - epoxy glue, coils are either connected in series with each other and a power source with a sinusoidal voltage of 50 Hz, or connected to individual power sources in the form of inverter converters through individual control units. 2. A method of manufacturing an electromagnetic apparatus of the vortex layer, including the manufacture of an inductor from electrical steel, bonding the elements of the inductor to each other, boring the inductor, placing the reaction chamber in the bore of the inductor, placing coils connected to the power source on the inductor, characterized in that the manufacture of the inductor magnetic circuit is carried out in the form of a toroid made of rolled electrical steel by winding the tape along the "Archimedes spiral", fastening individual turns of the toroid to each other hardened by applying a fixing hardener in the form of epoxy adhesive on the tape during winding, the inductor is bored after the fixing hardener is solidified by cutting a separate sector from the toroid with a profile corresponding to the profile of the reaction chamber, and the inductor coils are wound in advance and placed on the inductor through the bore in the toroid.

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