Cellulose Toggle Pressing Module for Compact Non-Flat Forming
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Solution Overview
Problem
Existing cellulose product forming technologies face challenges with high costs, large size, and complexity in manufacturing non-flat products using air-formed cellulose blank structures, particularly due to the use of conventional hydraulic or servo presses, which are costly and cumbersome, and require complex integration and engineering skills.
Innovation Solution
A cellulose product toggle pressing module utilizing a toggle mechanism with an electronic control system for precise control of pressing force, integrated with a blank dry-forming module, enabling compact, low-cost, and standardized production units that can be easily shipped and installed, eliminating the need for large buffer apparatus and allowing synchronized operation of the forming wire and toggle press.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If conventional hydraulic or servo presses are used for forming non-flat cellulose products, then high pressing capacity is achieved, but cost and device size increase significantly
Solution Approach 1:
The pressing module is divided into a toggle mechanism component and a pressing component. The toggle mechanism amplifies the pressing force from a smaller actuator, eliminating the need for large hydraulic or servo presses while maintaining high pressing capacity. This segmentation allows the system to achieve high force output without requiring a large overall device size.
Solution Approach 2:
The toggle mechanism acts as an intermediary between the actuator and the pressing component. It transmits and amplifies the pressing force, enabling a small actuator to generate high pressing capacity through mechanical advantage. This intermediary mechanism resolves the contradiction by providing force multiplication without requiring a large direct-acting press.
2Force
If conventional hydraulic or servo presses are used, then high pressing capacity is achieved, but manufacturing cost increases
Solution Approach 1:
The toggle mechanism uses simple mechanical components that are cheaper to manufacture than hydraulic or servo press systems. The mechanism relies on basic mechanical elements like links and pivots rather than expensive hydraulic systems or servo motors, significantly reducing manufacturing cost while maintaining high pressing capacity.
Solution Approach 2:
The invention replaces complex hydraulic or servo mechanical systems with a simpler toggle mechanism. This substitution eliminates the need for expensive hydraulic fluids, pumps, valves, or servo motors, reducing manufacturing cost while achieving the required pressing capacity through mechanical advantage.
3Stability of the object's composition
If large buffer apparatus are used in integrated production units, then material supply stability is improved, but device complexity and space requirements increase
Solution Approach 1:
The invention removes the buffer apparatus from the integrated production unit, eliminating the need for large storage spaces and complex material handling systems. The toggle press is designed to operate synchronously with the forming wire, allowing direct material supply without intermediate buffering, thus reducing device complexity while maintaining supply stability.
Solution Approach 2:
The system achieves material supply stability through self-synchronization between the forming wire and toggle press operation. The process is designed to coordinate naturally without requiring external buffer systems, allowing the production unit to serve itself by matching material supply with processing speed through coordinated operation.
4Productivity
If synchronized operation of forming wire and toggle press is implemented, then productivity is improved, but control complexity increases
Solution Approach 1:
The electronic control system uses feedback from sensors detecting the position and state of the forming wire and toggle press to coordinate their operation. This feedback mechanism allows the system to synchronize the forming wire speed with the toggle press cycle automatically, improving productivity while keeping control complexity manageable through automated closed-loop control.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a cost-effective, compact, and efficient method for forming non-flat cellulose products with precise control over pressing force, reducing cycle time and overall production costs, and enabling easy installation and operation without requiring extensive engineering expertise.
Implementation Method 1
a toggle mechanism (6e) drivingly connected to the pressing member (6d), and a pressing actuator arrangement (6f) drivingly connected to the toggle mechanism (6e)
Data Source
Figure 1a
Figure 1b
Figure 1c~1e
AI summary
A product forming unit (U) for manufacturing non-flat cellulose products (1) from an air-formed cellulose blank structure (2). The product forming unit (U) comprises a blank dry-forming module (4) with a moveable forming wire (4c), a toggle pressing module (6) with a toggle press (6a) and a forming mould (3), and an electronic control system (6h) operatively connected to the forming wire (4c) and the toggle press (6a). The blank dry-forming module (4) is configured for air-forming the cellulose blank structure (2) onto the forming wire (4c). The toggle press (6a) includes a pressing member (6d) movably arranged in a pressing direction, a toggle-mechanism (6e) drivingly connected to the pressing member (6d), a pressing actuator arrangement (6f) drivingly connected to the toggle-mechanism (6e). The forming mould (3) includes a moveable first mould part (3a) attached to the pressing member (6d) and a second mould part (3b). The electronic control system (6h) is configured for controlling operation of the pressing actuator arrangement (6f) for performing pressing operations, which involves driving the pressing member (6d) in the pressing direction by means of the toggle-mechanism (6e), and thereby forming the non-flat cellulose product from the air-formed cellulose blank structure by pressing the first mould part (3a) against the second mould part (3b). The electronic control system (6h) further is configured for intermittently feeding the forming wire (4c) between subsequent pressing operations.