Patent Description:
Apparatuses for separating liquid from solid material or solid matter or dry matter or shorter from solids are commonly used in agriculture, industry and in many other contexts. That kind of separating apparatus is also called a separator. In these devices, the separation of the dry matter from the liquid is carried out by a compression screw that can be also called a helical auger. The compression screw compresses the liquid from the material through the perforated surface of the drum-like screen around the compression screw and conveys the dry matter thus obtained for further use.

In the prior art solutions one disadvantage is the amount of solid materials in the slurry to be separated. Such solids as hay or straw materials and/or other solids easily build up large and tough clumps and piles that wrap around the first end of the compression screw. That decreases the slurry input to the separator apparatus and also the capacity and reliability of the separator. This also increases the need to clean the separator apparatus and thus binds labor.

Also, in the prior art, separators are commonly constructed so that a clearance between the inner surface of the drum-like screen and the outer periphery of the helical screw blade or flighting of the compression screw is as small as possible. The problem in this case is wear of the inner surface of the screen and the outer periphery of the flighting.

Such a wear is corrected by hard welding and turning which causes additional costs and loss of time and loss of capacity.

These kinds of separators operate as expected when a so-called dry matter stopper builds up from the material to be separated in the dry end of the separator. One problem in the prior art solutions is often the fact that the dry matter stopper does not build up fast enough in the starting phase of the separation. Another problem related to the dry matter stopper is that it does not keep steady enough during the separation. In that case too much slurry liquid gets into the dry matter, which spoils the dry matter and also forces the separation process to be interrupted. Also, some cleaning must be done which consumes time and binds labor.

A solution according to the European patent publication No. <CIT> is known in the prior art. The solution is related to a scraper filter system for removing solid components deposited on the surface of a filter element. The solid components come from viscous substances, such as liquids, slurries of soybean, ground fish meat or devil's tongue starch. These materials are relatively easy to handle, and they do not cause a lot of heavy pressure on the spiral impeller blades of the solution.

Also, the Finnish patent publication No. <CIT> discloses an apparatus according to the preamble of claim <NUM>.

The object of the present invention is to eliminate the above-mentioned disadvantages and to provide a simple and inexpensive and at the same time reliable structure for a separator apparatus comprising a compression screw and a screen around it. It is also an object of the present invention to provide a structure which allows greater tolerances between the compression screw and the screen and which improves the reliability, dependability, efficiency, and service life of the apparatus. In addition, one object of the invention is to provide an easily replaceable spare part for the compression screw of the separator apparatus. Also, one object of the invention is to achieve a solution where hay material, straws or other solids in the slurry do not cause clogging problems in the separation process. Yet one object of the invention is to achieve a solution where the dry matter stopper builds up as fast as possible in the second end of the separator and where the dry matter stopper keeps as steady as possible during the separation process. The apparatus according to the present invention is characterized by what is presented in the characterization part of claim <NUM>. Other embodiments of the invention are characterized by what is presented in the other claims.

An aspect of the invention is to provide an apparatus for separating liquid and solid material from each other, which apparatus comprises at least a drum-type screen and a compression screw equipped with a rotating shaft and a flighting and placed to extend through the screen, and which flighting is equipped with a pressure element made of flexible material. According to the invention, the apparatus comprises in the longitudinal direction of the compression screw various sections in each of which the rotating shaft comprises operational structures suited to the operation of that particular section.

The solution of the invention has significant advantages over the solutions of the prior art. Among other things, one advantage of the apparatus is that a separate pressure element mounted on the screw blade or flighting of the compression screw improves the reliability, efficiency, and service life of the apparatus. In addition, a separately installed pressure element allows greater tolerances between the flighting of the compression screw and the inner surface of the screen, which also improves wear resistance.

In the following, the invention will be described in detail by the aid of examples by referring to the attached simplified and diagrammatic drawings, wherein.

<FIG> shows schematically, in a simplified manner and partially cross-sectioned one separator apparatus in which the solution according to the invention can be used. The apparatus comprises at least a frame <NUM>, an operating machinery <NUM>, a slurry container <NUM>, a dewatering chamber <NUM> and a dry end <NUM> that is in the area of the second end of the frame <NUM>. The slurry container <NUM> comprises at least one inlet for feeding slurry material to be separated. The slurry material may be, for example, liquid animal manure originated in agriculture. In addition, the separator apparatus may comprise a conveyor <NUM> to move the separated dry matter for further use. Advantageously, the separator apparatus also comprises a control and electric unit <NUM> for controlling and powering the separator apparatus.

For the separation or dewatering the separator apparatus comprises an auger-type compression screw <NUM> that in arranged to rotate partially inside a drum-type screen <NUM> that is placed inside the dewatering chamber <NUM>. Preferably, the separator apparatus also comprises a cutting element <NUM> with cutting edges 9a placed inside the slurry container <NUM> and arranged around the first end of the compression screw <NUM>.

Later in this context the term first side or first end means the part or area that is on the side of the operating machinery <NUM> and the term second side or second end means the part or area that is on the side of the dry end <NUM>.

Preferably, the frame <NUM> is a free-standing structure having a support for the operating machinery <NUM> in its first end, which operating machinery <NUM> comprises a driving motor 2a and preferably a gearbox 2b. Heading to the second end of the frame <NUM> the slurry container <NUM> is placed after the operating machinery <NUM> which slurry container <NUM> is preferably fastened to the frame <NUM>. The secondary shaft 2c of the operating machinery <NUM> transmits the kinetic energy of the driving motor 2a through the gearbox 2b to the compression screw <NUM>. The first end of the compression screw <NUM> is placed inside the slurry container <NUM> from which the compression screw <NUM> extends into the dewatering chamber <NUM>. Preferably, the compression screw <NUM> comprises a central or rotating shaft 8a, a helical screw blade or flighting <NUM> around the rotating shaft 8a and a discharge end 8c at the second end of the rotating shaft 8a. The flighting <NUM> extends from the first end area of the rotating shaft 8a towards the second end of the rotating shaft 8a, preferably covering a part of the length of the rotating shaft 8a.

In relation to the operating machinery <NUM> the dewatering chamber <NUM> is behind the slurry container <NUM>. The dewatering chamber <NUM> comprises the drum-type screen <NUM> in its inside as mentioned above. The screen <NUM> has a cylindrical drum containing openings or apertures for the passage of liquid. The compression screw <NUM> is placed to extend through the drum inside the drum of the screen <NUM> so that the first end of the rotating shaft 8a of the compression screw <NUM> is in the slurry container <NUM> outside the screen <NUM> and the second end of the of the rotating shaft 8a extends out of the screen <NUM> to the dry end <NUM>. A collector tray 4a for separated liquid is placed under the drum of the screen <NUM>.

The compression screw <NUM> according to the invention preferably comprises at least three sequential sections or zones A, B and C which each may have a different structure in relation to the flighting <NUM> around the rotating shaft 8a. The section A is in the area of the first end of the compression screw <NUM>, section B is in the area of screen <NUM> and section C is in the area of the second end of rotating shaft 8a, partially inside the screen <NUM>. The structure of each section will be explained later.

When the compression screw <NUM> is rotated the flighting <NUM> pushes the material to be separated towards the second end of the compression screw <NUM>. In that case the material to be separated causes a counter pressure against flighting <NUM> onto the pressure side of the flighting <NUM>. The pressure side is the side facing towards the second end of the compression screw <NUM>, and can also be called as the second side.

<FIG> present in a simplified and diagrammatic way enlarged views of the structures related to the first end of the compression screw <NUM> of the apparatus according to the invention. <FIG> presents the first end of the compression screw <NUM> itself in a side view, <FIG> presents an enlarged top view of the first end area of the compression screw <NUM> in a partially cross-sectioned slurry container <NUM> that is in connection with a partially cross-sectioned dewatering chamber <NUM>, <FIG> presents an enlarged side view of the cross-sectioned cutting element <NUM>, and <FIG> presents an enlarged top view of a cross-sectioned cutting element <NUM>.

<FIG> presents the first end of the compression screw <NUM> according to the invention in a side view. Preferably, in the area of section A the first end of the compression screw <NUM> comprises the flighting <NUM> that is matched in a close relationship with the inner diameter of the cutting element <NUM>. The outer edge 9a of the flighting <NUM> on the periphery of the flighting <NUM> is arranged to a scissors-like shearing action with the cutting edges 11a of the cutting element <NUM>, as the rotating helix shaped flighting <NUM> passes over the stationary cutting edges 11a.

The length of the flighting <NUM> extends to the area of the second end of the cutting element <NUM> and ends before the screen <NUM>. As mentioned earlier, this part of the compression screw <NUM> comprises the section A and is placed preferably in the slurry container <NUM>. In the section A the structure of the flighting <NUM> may differ from structures of the flighting <NUM> in section B and C. Preferebly, the structure of the flighting <NUM> in the section A is made to endure cutting strains caused by hay, straws and other solids. Thus, the material of the flighting <NUM>, especially in the outer periphery of the flighting <NUM>, in the section A may be more wear-resistant and harder than the material the flighting <NUM> in the sections B and/or C.

After the section A begins the section B where the structure of the flighting <NUM> is preferably different. The flighting <NUM> may still be similar to the flighting <NUM> in the section A but in the section B a pressure element <NUM> is fastened with fastening elements <NUM> onto the second side or pressure side of the flighting <NUM>. The second side of the flighting <NUM> is facing towards the second end of the compression screw <NUM> as mentioned earlier. Thus, when the compression screw <NUM> rotates the pressure element <NUM> presses and conveys the slurry material towards the second end of the compression screw <NUM>.

<FIG> present an enlarged view of the first end of the compression screw <NUM> of the apparatus in a partially cross-sectioned slurry container <NUM> in connection with a partially cross-sectioned dewatering chamber <NUM>. The cutting element <NUM> is used to cut solid materials in the slurry, such solids as hay or straw materials and/or other solids, into smaller pieces before the liquid separation.

The cutting element <NUM> is in its basic shape a cylinder with a flat annular fastening flange 11b in its second end. Seeing from the first end of the compression screw <NUM> towards its second end the flange 11b is fastened to its place around the compression screw <NUM> just before the dewatering chamber <NUM>. The annular flange 11b also has a center hole 11c for the compression screw <NUM> to go through.

In its open first end the cutting element <NUM> comprises preferably two or more feed openings 11d which can be mutually similar with each other. The feed openings 11d open towards the first end of the cutting element <NUM>, taper curvilinearly towards the second end of the cutting element <NUM> and close before the second end of the cutting element <NUM>. Thus, the curvilinear, sharp-edged sides of the feed openings 11d form cutting edges 11a which correspond to the outer edge 9a of the periphery of the flighting <NUM> in the area of section A in the first end of the compression screw <NUM>.

The flighting <NUM> and the outer edge 9a of the flighting <NUM> in the first end of the compression screw <NUM> together with the cutting element <NUM> and its feed openings 11d and cutting edges 11a form a cutting mechanism for cutting and breaking long hay and straw and clumps and piles of hay, straw and other similar solids into smaller pieces in the first end of the compression screw <NUM> before the liquid separation process.

<FIG> presents in a simplified and diagrammatic way a side view of a part of a compression screw <NUM> of the apparatus according to the invention. Preferably, the compression screw <NUM> comprises the pressure element <NUM> that is fastened onto the second side of the flighting <NUM> with fastening elements <NUM>. Intentionally, the view of <FIG> is like a fisheye view so that both the flighting <NUM> and the pressure element <NUM> are clearly visible in the same figure.

Preferably, the pressure element <NUM> is placed onto the side of the flighting <NUM> in the area of section B that is in the area of the screen <NUM>. In that case, the pressure element <NUM> is fastened, preferably as a continuous element into the flighting <NUM> that rotates inside the screen <NUM>. The continuous element here means that individual pressure elements <NUM> are fastened into the flighting <NUM> one after the other to abut each other with their ends.

Preferably, the pressure elements <NUM> are in the flighting <NUM> at least in the area of the first end of the screen <NUM>, advantageously so that at least two, three or four first laps of the flighting <NUM> are inside the screen <NUM>. Depending on the slurry material to be separated the coverage of the pressure elements <NUM> may be more than four first laps of the flighting <NUM> inside the screen <NUM>. At maximum, the coverage may comprise all the laps of the flighting <NUM> inside the screen <NUM>.

<FIG> presents in a simplified and diagrammatic way and partially cross-sectioned a side view of the dry end <NUM> or second end of the separator apparatus according to the invention in a situation where the dry end <NUM> and the drum of the screen <NUM> are empty. This area of the compression screw <NUM> belongs to the section C as mentioned above. Preferably, the first part of the section C is inside the screen <NUM> and the second part of the section C is in the dry end <NUM> outside the dewatering chamber <NUM> and outside the screen <NUM>. In the section C the compression screw <NUM> preferably does not have the flighting <NUM> anymore. The plain rotation shaft 8a makes it possible to create a free space 10a inside the screen <NUM> in order to create a dry matter stopper or plug which builds up from the dry matter in the space 10a preferably immediately in the initial phase of the separation process and keeps stable and fully operational during the whole separation time.

The structure of the apparatus according to the invention in the section C makes the above mentioned well-functioning dry matter stopper possible. The structure comprises the free space 10a without the flighting <NUM> in the second end of the screen <NUM>, a reducing element <NUM> in connection with the second end of the drum of the screen <NUM>, and a counter-pressure element <NUM> in connection with the reducing element <NUM>. The reducing element <NUM> and counter-pressure element <NUM> are preferably fastened into their position at the second end area of the screen <NUM> by the help of an annular fastening ring <NUM>.

The free space 10a and its length are important for determining the dry matter content of the dry matter. The greater the length of the free space 10a, the drier dry matter is obtained. Suitably, the relation of the length of the free space 10a to the inner diameter of the drum of the screen <NUM> is, for example, between <NUM>,<NUM>. <NUM>,<NUM>. Preferably, the said relation is between <NUM>,<NUM>. <NUM>,<NUM>.

The reducing element <NUM> is a flat annular plate with a center hole. The diameter of the center hole is smaller than the inner diameter of the drum of the screen <NUM> in the second end of the screen <NUM>. In that case, the reducing element <NUM> forms a shoulder structure to prevent the material to be separated from flowing freely out from the screen <NUM>. The shoulder structure is arranged to slow down the sliding of the dry matter stopper in which case the compression pressure increases in the system. Even a small restriction in the passing through opening in the second end of the screen makes the dry matter content bigger. The liquid content in the dry matter is adjusted with the diameter size of the reducing element <NUM>. Preferably, the reducing element <NUM> is easily interchangeable. By replacing the reducing element <NUM> to another reducing element <NUM> with a smaller center hole the dry matter content can be increased and vice versa.

Preferably, the counter-pressure element <NUM> is made of unvulcanized rubber or caoutchouc. The counter-pressure element <NUM> is a flat annular plate with a center hole. The diameter of the center hole is preferably smaller than the outer diameter of the rotation shaft 8a at the position of the counter-pressure element <NUM>. In that case the counter-pressure element <NUM> is pressed tightly from its center hole onto the rotation shaft 8a. The counter-pressure element <NUM> is arranged to help creating a dry matter stopper as soon as possible after the separator apparatus has been started and to maintain the dry matter stopper as stable as possible.

The dry end <NUM> of the separator apparatus further has a monitoring element <NUM>, for example a limit switch arranged to monitor the state of the counter-pressure element <NUM>. The monitoring element <NUM> is in contact with the counter-pressure element <NUM>. When the separation is in progress, the counter-pressure element <NUM> is compressed outwards from its basic position, towards the second end of the rotating shaft 8a, so that the diameter of the center hole of the counter-pressure element <NUM> increases and its edges rise off the rotating shaft 8a of the compression screw <NUM>. In that case, the lever arm 17a of the monitoring element <NUM>, which lever arm 17a rests on the outer surface of the counter-pressure element <NUM>, turns with an increase in the diameter of the center hole and informs the control and electric unit <NUM> of the position of the counter-pressure element <NUM>. If, for some reason the dry matter stopper disappears during separation, the counter-pressure element <NUM> returns to its basic position, whereby the lever arm 17a returns along with the counter-pressure element <NUM> and switches off the control voltage at a predetermined position.

<FIG> presents in a simplified front view an annular pressure element <NUM> according to the invention. The pressure element <NUM> according to the invention is a flat annular plate with a center hole 12c whose diameter is bigger than the outer diameter of the rotation shaft 8a of the compression screw <NUM>. Advantageously, the pressure element <NUM> is flexible material, such as rubber or polyurethane. In <FIG> the pressure element <NUM> is partially equipped with fastening elements <NUM> that are used to fasten the pressure element <NUM> into flighting <NUM> of the compression screw <NUM>. For the fastening the pressure element <NUM> comprises fastening holes 12a that are preferably closer to the outer periphery 12b of the pressure element <NUM> than the inner periphery 12c of the pressure element <NUM>. That makes the fastening more stable and stronger.

<FIG> present in a simplified and diagrammatic way the helical flighting <NUM> of the compression screw <NUM> according to the invention in the cross-section along the section line D-D in <FIG>. In the situation of <FIG> the pressure element <NUM> is in its position but unfastened and without the fastening element <NUM>, and in the situation of <FIG> the pressure element <NUM> is fastened to the flighting <NUM> of the compression screw <NUM> with the fastening element <NUM> of the pressure element <NUM>.

At least in the section B the outer diameter of the base flighting <NUM> is smaller than the inner diameter of the drum of the screen <NUM>. In that case the structure comprises a gap or tolerance between the outer periphery of the flighting <NUM> and the inner surface of the drum of the screen <NUM>. Whereas the outer periphery of the pressure element <NUM> follows the outer periphery of the flighting <NUM> but the outer periphery of the pressure element <NUM> extends in radial direction beyond the outer periphery of the flighting <NUM> a distance S that is greater than the gap between the outer periphery of the flighting <NUM> and the inner surface of the drum of the screen <NUM>. Preferably, the distance S is at least about <NUM> greater that the said gap. Thanks to this the outer edge or periphery of the pressure element <NUM> presses tightly against the inner surface of the drum of the screen <NUM> closing at the same time the said gap. Preferably the distance S is so large that a part of the outer surface of the pressure element <NUM> is pressed through the mesh apertures of the drum of the screen <NUM> thus keeping the apertures open.

The thickness W of the pressure element <NUM> is at least three times, preferably at least four times as large as the gap between the outer periphery of the flighting <NUM> and the inner surface of the drum of the screen <NUM>. That prevents the pressure element <NUM> from squeezing into the gap between the outer periphery of the flighting <NUM> and the inner surface of the drum of the screen <NUM>.

Advantageously, the fastening structure has been arranged so that both the outer side surfaces, i.e. the first side surface of the flighting <NUM> and the second side surface of the pressure element <NUM> are as smooth as possible. That is important at least in the area of the section B where the structure comprises the pressure element <NUM>. In order to achieve a sufficient smoothness, both ends of the fastening elements <NUM> must be embedded in the side surfaces as has been done in the situation of <FIG>. For that purpose, the fastening hole 9c in the flighting <NUM> comprises a countersink on the first side surface of the flighting <NUM>. Whereas the pressure element <NUM> is flexible material which makes it possible that on the second side of the flighting <NUM> the flat head of the fastening element <NUM> will sit flush with or below the level of the side surface of the pressure element <NUM>.

<FIG> present in a simplified view the fastening element <NUM> of the pressure element <NUM> according to the invention. <FIG> presents the fastening element <NUM> in a side view, <FIG> presents a nut part 13b of the fastening element <NUM> in a back view and <FIG> presents the nut part 13b of the fastening element <NUM> in a front view.

The fastening element <NUM> preferably comprises two parts; a screw part 13a and a nut part 13b. The screw part 13b may be an ordinary screw with a countersunk head. The head of the screw part 13b is dimensioned so that the head sits flush with or below the level of first side surface of the flighting <NUM> when the fastening element <NUM> is fastened.

The nut part 13b comprises a screw bushing 13c and a flat plate 13d fastened into the first end of the screw bushing 13c. The screw bushing 13c has an inside thread that matches with the outside thread of the screw part 13a. Preferably, the thickness of the plate 13d is so small that the plate 13d can easily be embedded in the flexible second side surface of the pressure element <NUM> when the pressure element <NUM> is fastened into its position.

It is obvious to the person skilled in the art that the invention is not restricted to the examples described above but that it may be varied within the scope of the claims presented below. Thus, for example, the structures and components of separator apparatus may be different from what is presented.

It is also obvious to the person skilled in the art that the embedding of the fastening elements may be done in a different way as presented above. For instance, instead of using countersinking and countersunk screws counterboring and corresponding screws may be used when fastening the pressure elements. It is important that outwards facing surfaces of the flighting, especially in the area of the section B inside the screen, are as smooth as possible in order to prevent sticking of the material to be separated to the flighting.

It is still obvious to the person skilled in the art that the apparatus according to the invention can be also used for separation of other material than slurry.

Claim 1:
Apparatus for separating liquid and solid material from each other, which apparatus comprises at least a drum-type screen (<NUM>) and a compression screw (<NUM>) equipped with a rotation shaft (8a) and a flighting (<NUM>) and placed to extend through the screen (<NUM>), and which flighting (<NUM>) comprises an outer edge (9a) on its periphery and is equipped with a pressure element (<NUM>) made advantageously of flexible material and fastened onto the pressure side of the flighting (<NUM>) facing towards the second end of the compression screw (<NUM>), and which apparatus comprises in the longitudinal direction of the compression screw (<NUM>) a first section (A), a second section (B) and a third section (C), where in the area of the first section (A) which area is in the area of the first end of the compression screw (<NUM>) the apparatus comprises a cutting element (<NUM>) which together with the outer edge (9a) of the flighting (<NUM>) forms a cutting mechanism for cutting hay, straws and other solid material into smaller pieces, characterized in that the pressure element (<NUM>) is in the area of the second section (B) which area is in the area of the screen (<NUM>), and that the single pressure element (<NUM>) is a flat annular plate with a center hole (12c) whose diameter is bigger than the outer diameter of the rotation shaft (8a) of the compression screw (<NUM>).