Dynamic self-adaptive tensioning system for vertical filter press

Abstract

The utility model discloses a dynamic self -adaptation tensioning system for vertical filter press, including filter plate subassembly, cleaning assembly, PLC controller and multiple groups of roller body. Filter cloth is formed circulation through filter cloth drive roll, redirection roll etc. Tensioning mobile roller cooperation displacement sensor, guyed sensor and PLC constitute closed -loop control, and dynamic regulation tensioning force. Can prolong the life of component, improve operating stability and production benefit, be applicable to various filtering scene.

Description

Technical Field

[0001] This utility model relates to the field of vertical filter press technology, and specifically to a dynamic adaptive tensioning system for a vertical filter press. Background Technology

[0002] During the operation of a vertical filter press, the performance of the tensioning system directly affects the stable operation and production efficiency of the equipment. Traditional vertical filter press tensioning systems generally use hydraulic drive, adjusting the tension force by moving the tension rollers via a chain transmission mechanism. For filter cloth drive, a combination of one main drive roller and 2-4 auxiliary drive rollers is typically used. This combination works adequately under low loads. However, if the production system experiences malfunctions, such as insufficient drying efficiency due to various reasons—increased moisture content leading to a significant increase in load—the system may be unable to drive the filter cloth effectively. This relatively dispersed drive combination has significant drawbacks. Due to the dispersed drive, each drive group needs to output relatively more power to meet the discharge requirements, directly increasing the driving force of each roller, thus forcing the tensioning system to provide additional tension force. This additional tension force significantly increases the system load, and the continuous application of this large tension force to the equipment places excessive strain on it, leading to a series of problems.

[0003] Furthermore, traditional tensioning systems cannot adjust the tension force in real time according to changes in load, leading to unstable equipment operation. Frequent equipment failures and component damage also disrupt production plans, further impacting the company's normal production rhythm and economic benefits. These problems have long plagued relevant enterprises, becoming significant factors restricting the efficient and stable operation of vertical filter presses. Utility Model Content

[0004] To address the problems existing in the prior art, this utility model provides a dynamic adaptive tensioning system for vertical filter presses, aiming to solve the problems of high equipment load, easy component damage, and unstable operation of traditional vertical filter press tensioning systems, and to achieve dynamic adaptive adjustment of tension force, thereby improving the stability of equipment operation and service life.

[0005] To achieve the above objectives, the present invention employs the following technical means:

[0006] A dynamic adaptive tensioning system for a vertical filter press includes a filter plate assembly, a cleaning assembly, and a PLC controller. One side of the filter plate assembly is connected to multiple sets of filter cloth drive rollers, and the other side is connected to multiple sets of filter cloth redirecting rollers, tensioning upper redirecting rollers, tension adjusting rollers, and correction rollers. The cleaning assembly contains drive rollers and multiple sets of redirecting rollers internally, and a cleaning upper redirecting roller is externally connected to the cleaning assembly. The multiple sets of filter cloth drive rollers are connected to each other by a filter cloth that passes through the filter plate assembly and wraps around a corresponding set of filter cloth redirecting rollers. One end of the filter cloth redirecting roller is connected to the tension adjusting roller via a filter cloth wrapping around the tensioning upper redirecting roller. The tension adjusting roller is connected to a set of redirecting rollers via a filter cloth wrapping around the correction roller. The redirecting rollers of one group are connected to another group of redirecting rollers via a filter cloth winding drive roller. The other group of redirecting rollers is connected to the filter cloth redirecting roller at the other end via a filter cloth winding cleaning upper redirecting roller. The filter cloth drive roller and the drive roller are electrically connected to the PLC controller. The tensioning upper redirecting roller is connected to the tensioning adjusting roller via a filter cloth winding tensioning moving roller. A tensioning moving roller has a pull wire sensor connected to the filter plate assembly on one side. The tensioning moving roller is connected to a screw drive servo motor connected to the filter plate assembly via a ball screw. A displacement sensor connected to the filter plate assembly is located on one side of the tensioning adjusting roller. The pull wire sensor, the displacement sensor, and the screw drive servo motor are electrically connected to the PLC controller.

[0007] Preferably, the filter cloth drive roller has the same structure as the drive roller, both consisting of a roller shaft and a servo motor, with the servo motor driving the roller shaft to rotate.

[0008] This utility model has the following beneficial effects:

[0009] 1. Achieving Dynamic Adaptive Tension Adjustment: This system monitors the position information of the tension adjustment roller and the tension moving roller in real time through displacement sensors and tension wire sensors, and feeds the data back to the PLC controller. Based on the comparison between preset thresholds and real-time data, the PLC controller adjusts the position of the tension moving roller via a lead screw-driven servo motor and ball screw, thereby dynamically changing the filter cloth tension. This closed-loop control mechanism enables the system to respond quickly to load changes and maintain appropriate tension at all times, solving the problem of traditional systems' inability to dynamically adjust tension.

[0010] 2. Extend the service life of key components: For filter cloth, because the tension is always within a reasonable range, it avoids damage caused by excessive tightness and problems such as misalignment and wear caused by excessive looseness, which significantly extends the service life of the filter cloth and reduces the frequency and cost of filter cloth replacement; the metal parts such as the support frame and roller bearings in the equipment no longer bear excessive additional loads, reducing the occurrence of bending deformation of the support frame and damage to the roller bearings due to overpressure, effectively improving the overall service life of the equipment and reducing equipment maintenance costs.

[0011] 3. Improved system operational stability: The filter cloth drive roller and drive roller with servo motors achieve uniform drive distribution, combined with a dynamic adaptive tensioning structure, making the filter cloth run more smoothly. This avoids the operational fluctuations caused by dispersed drive and unstable tension in traditional systems, reduces downtime due to equipment failure, and ensures production continuity.

[0012] 4. Improved Production Efficiency: The increased stability and reduced failure rate of the system make the production process smoother, effectively improving filtration efficiency and filter cake quality. At the same time, it reduces the time and cost of equipment maintenance and component replacement, indirectly improving the company's production and economic benefits. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the structure of this utility model;

[0014] In the attached figures, the following labels are used:

[0015] Filter cloth drive roller 1, filter cloth redirecting roller 2, tensioning upper redirecting roller 3, tension sensor 4, tension moving roller 5, tension adjusting roller 6, displacement sensor 7, correction roller 8, ball screw 9, screw drive servo motor 10, drive roller 11, redirecting roller 12, cleaning upper redirecting roller 13, PLC controller 14. Detailed Implementation

[0016] The technical solution of this utility model will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this utility model. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this utility model. Example 1

[0017] like Figure 1As shown, a dynamic adaptive tensioning system for a vertical filter press includes a filter plate assembly, a cleaning assembly, and a PLC controller 14. Multiple sets of filter cloth drive rollers 1 are connected to one side of the filter plate assembly, and multiple sets of filter cloth redirecting rollers 2, tensioning upper redirecting rollers 3, tension adjusting rollers 6, and correction rollers 8 are connected to the other side. The cleaning assembly contains drive rollers 11 and multiple sets of redirecting rollers 12, and an upper cleaning redirecting roller 13 is connected to the outside of the cleaning assembly. The multiple sets of filter cloth drive rollers 1 are connected to each other by a set of corresponding filter cloth redirecting rollers 2 wrapped around filter cloth that passes through the filter plate assembly. One end of the filter cloth redirecting roller 2 is connected to the tension adjusting roller 6 via a filter cloth wrapped around the tensioning upper redirecting roller 3. The tension adjusting roller 6 is connected to a set of redirecting rollers 12 via a filter cloth wrapped around the correction roller 8. Roller 12 is connected to another set of redirecting rollers 12 via filter cloth winding drive roller 11. The other set of redirecting rollers 12 is connected to the other end filter cloth redirecting roller 2 via filter cloth winding cleaning upper redirecting roller 13. Filter cloth drive roller 1 and drive roller 11 are electrically connected to PLC controller 14 respectively. Tensioning upper redirecting roller 3 is connected to tensioning adjusting roller 6 via filter cloth winding tensioning moving roller 5. One side of tensioning moving roller 5 is provided with a pull wire sensor 4 connected to the filter plate assembly. Tensioning moving roller 5 is connected to a screw drive servo motor 10 connected to the filter plate assembly via ball screw 9. One side of tensioning adjusting roller 6 is provided with a displacement sensor 7 connected to the filter plate assembly. Pull wire sensor 4, displacement sensor 7, and screw drive servo motor 10 are electrically connected to PLC controller 14 respectively.

[0018] The filter cloth drive roller 1 and drive roller 11 have the same structure, both consisting of a roller shaft and a servo motor, with the servo motor driving the roller shaft to rotate.

[0019] The beneficial effects of the above settings are:

[0020] Ensuring stable and precise drive force output: The servo motor has excellent speed regulation performance and control precision, enabling precise control of the roller's speed and rotation angle. The filter cloth drive roller 1 and drive roller 11 are driven by servo motors, which ensures stable and precise drive force output to the filter cloth, avoiding problems such as speed fluctuations and uneven drive force that may occur in traditional drive methods. This allows the filter cloth to maintain a stable motion state during operation, which is conducive to the smooth progress of filtration operations.

[0021] Facilitates synchronized operation: Since both components have the same structure and are driven by servo motors, they can more easily achieve synchronized operation under the unified control of PLC controller 14. Filter cloth drive roller 1 is responsible for driving the filter cloth to perform filtration at the filter plate assembly, while drive roller 11 drives the filter cloth to move at the cleaning assembly. The synchronized operation of both ensures that the filter cloth is subjected to uniform force and moves smoothly throughout the entire circulation path, avoiding additional tension or slack in the filter cloth due to speed differences, and further reducing the risk of wear and breakage of the filter cloth.

[0022] Reduced equipment maintenance difficulty and cost: Identical structures mean that the components are interchangeable, making equipment maintenance, whether it's replacing spare parts or performing repairs, much simpler. Maintenance personnel do not need to learn maintenance techniques or stock different spare parts for two different drive roller structures, reducing maintenance complexity and lowering maintenance costs and time.

[0023] Enhancing overall system control coordination: The servo motors can achieve precise digital control through the PLC controller 14. The filter cloth drive roller 1 and drive roller 11 adopt this driving method, which allows them to be better integrated into the closed-loop control of the entire system. Their operating status can be monitored and adjusted in real time by the PLC controller 14, working in coordination with other components such as the tensioning system. This makes the operation of the entire vertical filter press system more coordinated and efficient, further ensuring the quality and efficiency of operations in filtration, cleaning, and other stages.

[0024] Working principle

[0025] The working principle of the dynamic adaptive tensioning system of this vertical filter press is based on a closed-loop control mechanism. It achieves dynamic adaptive adjustment of the filter cloth tension through the coordinated operation of various components. The specific process is as follows:

[0026] First, during system operation, displacement sensor 7 collects position data of tension adjustment roller 6 in real time. This data reflects the current tension status of the filter cloth. Displacement sensor 7 transmits the collected data to PLC controller 14 in real time.

[0027] At the same time, the tension sensor 4 will detect the position of the tension moving roller 5 and feed back the detected position signal to the PLC controller 14.

[0028] After receiving the position data of the tension adjustment roller 6 from the displacement sensor 7, the PLC controller 14 processes and analyzes the data, and then compares the data with the preset threshold corresponding to the tension force and the position signal of the tension moving roller 5 fed back by the tension sensor 4.

[0029] Based on the comparison results, the PLC controller 14 generates the corresponding adjustment command and sends the command to the lead screw drive servo motor 10.

[0030] After receiving the adjustment command, the lead screw drive servo motor 10 starts working and drives the ball screw 9 connected to it to rotate. The rotation of the ball screw 9 will change the position of the tension moving roller 5.

[0031] When the position of the tensioning moving roller 5 changes, the tension of the filter cloth will be changed through the winding relationship of the filter cloth.

[0032] As the tension changes, the position of the tension adjusting roller 6 will change accordingly. The displacement sensor 7 will detect this change and transmit the new position signal to the PLC controller 14. At the same time, the position change of the tension moving roller 5 will also be captured by the wire sensor 4 and fed back to the PLC controller 14.

[0033] The PLC controller 14 processes and compares the newly received signals again, and sends adjustment commands to the lead screw drive servo motor 10 as needed. This process is repeated to form a complete closed-loop control, thereby ensuring that the system always maintains a suitable tension during operation and achieving dynamic adaptive adjustment. Example 2

[0034] Application of vertical filter press for sludge dewatering in municipal wastewater treatment plants

[0035] In a municipal wastewater treatment plant, a vertical filter press processing large quantities of sludge is equipped with this dynamic adaptive tensioning system. When the sludge enters the filter plate assembly, multiple sets of filter cloth drive rollers 1 rotate under the drive of servo motors, moving the filter cloth and completing sludge dewatering within the filter plate assembly. During this process, the filter cloth drive rollers 1 are connected to corresponding filter cloth redirecting rollers 2 through the filter cloth passing through the filter plate assembly. The filter cloth redirecting rollers 2 change the direction of the filter cloth, ensuring orderly movement of the filter cloth within the filter plate assembly.

[0036] After dehydration, the filter cloth needs to be cleaned in the cleaning assembly. The filter cloth redirecting roller 2 at one end guides the filter cloth to the tensioning upper redirecting roller 3. The filter cloth then wraps around the tensioning upper redirecting roller 3 to the tensioning moving roller 5, and then connects to the tension adjusting roller 6. At this time, the displacement sensor 7 monitors the position of the tension adjusting roller 6 in real time and transmits the data to the PLC controller 14. The tension cable sensor 4 also feeds back the position signal of the tensioning moving roller 5 to the PLC controller 14.

[0037] When the amount of sludge suddenly increases, the tension of the filter cloth increases, and the position of the tension adjusting roller 6 changes. The displacement sensor 7 detects this change. After comparing the preset threshold with the data from the tension sensor 4, the PLC controller 14 instructs the lead screw drive servo motor 10 to work, which drives the tension moving roller 5 to adjust its position via the ball screw 9, increasing the slack of the filter cloth to reduce tension. At the same time, when the filter cloth passes the correction roller 8, the correction roller 8 promptly corrects any possible deviation of the filter cloth, ensuring smooth operation of the filter cloth.

[0038] Subsequently, the filter cloth is connected to a set of redirecting rollers 12 via the correction roller 8. The redirecting rollers 12 change the direction of the filter cloth, allowing it to enter the cleaning assembly. Driven by the drive roller 11, the filter cloth is cleaned within the cleaning assembly by being guided by multiple sets of redirecting rollers 12. After cleaning, the filter cloth is wound around the filter cloth redirecting roller 2 at the other end via the cleaning redirecting roller 13, and then re-enters the filter plate assembly for cyclical operation. The entire process ensures stable system operation, significantly reducing filter cloth breakage rate and equipment failure. Example 3

[0039] Application of vertical filter press for juice filtration in food processing industry

[0040] A food processing company uses a vertical filter press to filter juice, and this system plays a crucial role. Filter cloth drive roller 1 drives the filter cloth to move within the filter plate assembly, while filter cloth redirection roller 2 guides the filter cloth, ensuring thorough filtration of the juice.

[0041] The filtered filter cloth passes sequentially through the tensioning upper redirecting roller 3, the tensioning moving roller 5, and the tension adjusting roller 6. When changes in juice concentration cause fluctuations in filter cloth tension, the displacement sensor 7 and the tension cable sensor 4 transmit relevant position data to the PLC controller 14. If the tension is too low, the PLC controller 14 controls the lead screw driven servo motor 10 to move the tensioning moving roller 5 via the ball screw 9, increasing the filter cloth tension. The position of the tension adjusting roller 6 changes accordingly, and the displacement sensor 7 feeds back the new data, forming a closed-loop control.

[0042] After the filter cloth is corrected by the alignment roller 8, it is guided by the redirecting roller 12 into the cleaning assembly, where it is cleaned under the action of the drive roller 11. The cleaned filter cloth then returns to the filtration stage via the redirecting roller 12, the upper cleaning redirecting roller 13, and the other end filter cloth redirecting roller 2. This system ensures smooth operation of the filter cloth, guarantees the accuracy of juice filtration, extends the service life of the equipment and the filter cloth, and improves production efficiency.

[0043] Specific experimental verification

[0044] Experimental Verification 1: Scenario Experiment of Sludge Dewatering in Municipal Wastewater Treatment Plant

[0045] Experimental objective: To verify the effect of the dynamic adaptive tensioning system on improving filter cloth breakage rate and equipment failure frequency under fluctuating sludge volume.

[0046] Experimental equipment: Two vertical filter presses of the same model, one equipped with this dynamic adaptive tensioning system (experimental group), and the other using a traditional tensioning system (control group).

[0047] Experimental parameters: The experimental period was 30 days, the daily sludge processing volume was basically the same, and it included 5 working conditions where the sludge volume suddenly increased (simulating sudden situations in actual production).

[0048] Experimental procedure:

[0049] Experimental group: The system operates according to the workflow of Example 2. When the amount of sludge suddenly increases, the system feeds back data through displacement sensor 7 and pull wire sensor 4. The PLC controller 14 controls the lead screw drive servo motor 10 and ball screw 9 to adjust the position of tensioning moving roller 5, thereby realizing dynamic adjustment of tension force.

[0050] Control group: The traditional hydraulic tensioning system could not adjust the tension in time when the amount of sludge suddenly increased.

[0051] Experimental results:

[0052] Filter cloth breakage rate: 1.2% in the experimental group and 8.5% in the control group. The filter cloth breakage rate in the experimental group was significantly lower.

[0053] Number of equipment failures: The experimental group experienced 2 failures due to issues such as bracket deformation and roller bearing damage, while the control group experienced 15 failures. The stability of the equipment in the experimental group was significantly improved.

[0054] Experimental Verification 2: Juice Filtration Scenario Experiment in the Food Processing Industry

[0055] Experimental objective: To verify the impact of changes in juice concentration on filtration accuracy, filter cloth lifespan, and production efficiency of this system.

[0056] Experimental equipment: Two vertical filter presses of the same specifications. The experimental group was equipped with this system, while the control group was equipped with the traditional system.

[0057] Experimental parameters: The experiment lasted for 20 days, with the same amount of filtered juice per day, and the juice concentration changed every 4 hours (covering low, medium and high concentrations).

[0058] Experimental procedure:

[0059] Experimental group: As described in Example 3, when the change in juice concentration causes fluctuations in filter cloth tension, the data is transmitted to the PLC controller 14 through the displacement sensor 7 and the tensioning moving roller 5 to maintain a suitable tension.

[0060] Control group: Traditional systems cannot adjust tension according to concentration changes.

[0061] Experimental results:

[0062] Filtration accuracy: The average impurity content of the juice after filtration in the experimental group was 0.02 g / L, while that in the control group was 0.15 g / L, indicating that the experimental group had higher filtration accuracy.

[0063] Filter cloth lifespan: The filter cloth replacement cycle in the experimental group was 45 days, while that in the control group was 18 days. The lifespan of the filter cloth in the experimental group was more than doubled.

[0064] Production efficiency: The experimental group had 2.3 hours more effective filtration time per day than the control group, resulting in a production efficiency increase of approximately 19%.

[0065] The examples provided in this utility model are not intended to limit the implementation methods. Those skilled in the art will recognize that various variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all possible implementation methods here, and any obvious variations or modifications derived therefrom are still within the protection scope of this utility model.

Claims

1. A dynamic adaptive tensioning system for a vertical filter press, comprising a filter plate assembly, a cleaning assembly, and a PLC controller (14), wherein one side of the filter plate assembly is connected to multiple sets of filter cloth drive rollers (1), and the other side of the filter plate assembly is connected to multiple sets of filter cloth redirecting rollers (2), tensioning upper redirecting rollers (3), tension adjusting rollers (6), and correction rollers (8), wherein the cleaning assembly is internally connected to drive rollers (11) and multiple sets of redirecting rollers (12), and externally connected to cleaning upper redirecting rollers (13), wherein the multiple sets of filter cloth drive rollers (1) are connected to a corresponding set of filter cloth redirecting rollers by filter cloth passing through the filter plate assembly. (2) Connecting, one end of the filter cloth redirecting roller (2) is connected to the tension adjusting roller (6) via the filter cloth winding tensioning upper redirecting roller (3), the tension adjusting roller (6) is connected to a set of redirecting rollers (12) via the filter cloth winding correction roller (8), one set of redirecting rollers (12) is connected to another set of redirecting rollers (12) via the filter cloth winding drive roller (11), the other set of redirecting rollers (12) is connected to the other end of the filter cloth redirecting roller (2) via the filter cloth winding cleaning upper redirecting roller (13), the filter cloth drive roller (1) and drive roller (11) are electrically connected to the PLC controller (14), characterized in that, The tensioning upper redirecting roller (3) is connected to the tensioning moving roller (5) via the filter cloth wrapping and the tensioning adjusting roller (6). One side of the tensioning moving roller (5) is provided with a pull wire sensor (4) connected to the filter plate assembly. The tensioning moving roller (5) is connected to a screw drive servo motor (10) connected to the filter plate assembly via a ball screw (9). One side of the tensioning adjusting roller (6) is provided with a displacement sensor (7) connected to the filter plate assembly. The pull wire sensor (4), displacement sensor (7), and screw drive servo motor (10) are electrically connected to the PLC controller (14).

2. The dynamic adaptive tensioning system for a vertical filter press according to claim 1, characterized in that, The filter cloth drive roller (1) and the drive roller (11) have the same structure, both consisting of a roller shaft and a servo motor, and the servo motor drives the roller shaft to rotate.

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