MATSYS Fluidized Filling System User Manual

User’s Guide:

Fluidized Filling System

45490 Ruritan Circle

Sterling, Virginia 20164

703.964.0400

[e-mail]

www.matsys.com

Table of Contents

• Introduction 2

• Fluidized Fill Shoe 2

• Control Cabinet 3

• Fluidization Principle 4

• System Set-up and Installation 5

• Gas Supply 5

• Fluidizer Control 6

• Mounting the Shoe 7

• Connection to Control Cabinet 8

• Initial Set-up 8

• Check-out Procedure 9

• Operation 10

• Fluidizer Care 10

• Calibration Chart A 12

• Appendix A – Quick Reference 13

• Appendix B – Operation 14

• Electrical Wiring Diagram 16

1

INTRODUCTION

The MATSYS Fluidized Fill Shoe System (FFS) is a powder delivery system

designed for consistent, fast and uniform filling of small die cavities. It can be used on a

wide variety of particulate materials. The FFS system includes a fluidized fill shoe and a

control cabinet. The fluidized fill shoe design incorporates two main components: a

transport tube and a delivery chute. Fluidization of the transport tube and delivery

chute is controlled separately using gas pressure control and individual adjustable flow

meters.

Fluidized Fill Shoe

The fluidized fill shoe design consists of two main components: a transport tube

and a delivery chute. These are independent gas chambers used to fluidize the

particulate material prior to delivery and fill of the die cavities. These chambers are

illustrated in Figure 1. Powder is supplied to the fluidized fill shoe by connecting a 2”

I.D. hose to the connection on the top of the fluidized fill shoe transport tube. The

fluidizing process begins in the transport tube and conveys the particulate material to

the delivery chute. When the particulate material reaches the delivery chute, two multi-

loop fluidizers, a top loop and a bottom loop, located inside the delivery chute keep the

particulate material in a fluidized or loose state until it reaches the die opening. These

two loop fluidizers inside the delivery chute are controlled independently.

Transport Tube

Delivery Chute

Figure 1. Illustration of the fluidized fill shoe components.

The following is a brief description of each of the fluidized fill shoe components:

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1. Transport tube. The transport tube provides the connection between the

particulate material supply hose and the delivery chute. It begins the process

of conditioning the particulate material to a fluidized or loose state and

conveys the particulate material to the delivery chute.

2. Delivery chute. The delivery chute functions as the powder discharge unit

directly above the die cavity. It has two multi-loop fluidizers, a top loop and

a bottom loop, to loosen and fluidize the particulate material before it

reaches the die opening.

Control Cabinet

The control cabinet houses the gas controls for the FFS system. These controls

regulate powder fluidization in relation to the movement of the fluidized fill shoe on the

press. An optional combination in-line moisture separator, filtration system and gas

dryer to remove moisture and solid contaminants from the gas supply. Three

independent pressure regulators (0-5 psi) and pneumatic solenoids are used to regulate

the flow of gas to each of the three FFS independent fluidizers, namely, the transport

and the two fluidizer loops inside the delivery chute. The solenoids are timed to control

fluidization of the powder when the fill shoe is over the die cavity. Three flow meters

(up to 30 SCFH) are used to independently monitor the gas flow to each of the three

fluidizers independently.

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FFS BASIC PRINCIPLE

Powder flows like a fluid when supported by a column of gas. The result is a

reduction in the effects of head pressure, clumping and surge, both of which are

common in gravity fed systems. The fluidized fill shoe creates a low pressure gas

bearing below the powder inside the shoe to reduce the friction along the powder path

to the fill point.

The FFS was developed to improve powder flow consistency, powder flow

uniformity, increase powder flow rates, and improve the speed of filling die cavities. By

flowing gas through a bed of solid particles from the bottom to the top, the bed is

loosened and fluidized, and particles are easier to move. The FFS uses a dry gas, such as

air, nitrogen, or argon to “coat” particles and separate them, thereby greatly reducing

inter-particle friction, improving powder flow consistency, and increasing powder flow

rates. The gas provides a transport mechanism reducing inter-particle friction and

thereby reducing the need for bulk lubricants in the powder blend.

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SYSTEM SETUP AND INSTALLATION

1. Gas Supply

The most optimal method of fluidizing is to use an inert gas such as Argon,

alternatively compressed air can be used when properly treated, dried and filtered.

When a compressed air source is used to supply air pressure to the fluidized fill shoe,

the gas control supply pressure should be between 30 and 60 psi. The FFS control

cabinet will provide instrument quality air to the fluidized fill shoe as long as care is

taken to maintain a quality air supply, i.e. air that is free of oil, dirt, and moisture. To

prevent moisture build up in the gas lines it is common practice to install an

appropriately sized after-cooler and moisture separator system on a shop air

compressor. As an extra precaution, it is recommended that a secondary liquid

separator and trap be installed ahead of the FFS control cabinet as shown in Figure 2.

During normal use, and especially during initial setup of a new system, the

quality of the air supply should be closely monitored for any oil, moisture, or solid

contamination.

For systems equipped with a desiccant dryer

The functionality of a desiccant gas dryer can be readily checked by observing

the dew-point indicator particles which are mixed into the desiccant located inside the

dryer:

♦ When the indicator particles color is blue, the dryer function is normal and it

is O.K. to operate the system.

♦ When the indicator particles color is pink, the outlet air is humid. It is time to

replace the desiccant before you operate the system.

For systems equipped with a membrane dryer (optional)

The desiccant dryer can be upgraded to a very low maintenance membrane

dryer. With a membrane dryer you can readily check outlet moisture condition by

observing the dew-point indicator which is located on the top of the membrane dryer:

♦ When the dew-point indicator is blue, the operation is normal.
♦ When the dew-point indicator is pink, the outlet air is humid.

Note: It takes approximately 1 hour to change the color of the dew-point

indicator from the start-up of supply air.

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