Combination flow tunnel
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Solution Overview
Problem
Existing washing machines, particularly continuous batch tunnel washers, face inefficiencies in washing and rinsing processes, requiring multiple modules and high manufacturing costs due to the need for counterflow rinsing and multiple modules with outer shells.
Innovation Solution
The implementation of a continuous batch tunnel washer with a high-velocity rinsing system that reduces the number of modules required by using perforated scoops and outer shells in rinse modules, and carryover modules without shells, allowing for efficient rinsing and washing with fewer drums and lower manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If counterflow rinsing is used in all modules with outer shells, then rinsing performance is improved, but manufacturing cost and device complexity increase
Solution Approach 1:
The tunnel washer is divided into different module types: rinse modules with outer shells and perforated scoops for counterflow rinsing, and carryover modules without shells for simple fabric transfer. This segmentation allows each module to be optimized for its specific function, reducing overall complexity while maintaining rinsing performance in the dedicated rinse modules.
Solution Approach 2:
Different modules have different structural qualities tailored to their functions. Rinse modules have outer shells and perforated scoops to enable counterflow rinsing, while carryover modules have simplified construction without shells. This local differentiation optimizes the system by applying complex structures only where needed for rinsing.
2Productivity
If multiple modules with outer shells are used for counterflow rinsing, then rinsing efficiency is improved, but manufacturing cost increases
Solution Approach 1:
The system segments modules into rinse modules (with shells for efficient rinsing) and carryover modules (without shells for cost-effective fabric transfer). This allows the system to achieve rinsing efficiency in dedicated modules while reducing manufacturing costs by eliminating unnecessary shells from transport modules.
Solution Approach 2:
Carryover modules use simplified construction without expensive outer shells, as their function is merely to transfer fabric articles between rinse modules. This reduces manufacturing cost for modules that do not require the complex structure needed for rinsing operations.
3Reliability
If all modules have perforated scoops and outer shells, then washing function is improved, but device complexity and cost increase
Solution Approach 1:
The tunnel washer is segmented into rinse modules with complete structures (shells and perforated scoops) for washing functions, and carryover modules with simplified structures for fabric transfer only. This segmentation ensures washing function is fully implemented where needed while reducing complexity in transport sections.
Solution Approach 2:
Complete washing functionality with outer shells and perforated scoops is applied locally only to rinse modules, while carryover modules have simplified construction. This local quality approach ensures washing performance is maintained in dedicated rinse zones without unnecessarily complicating the entire system.
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
This solution enhances washing and rinsing efficiency with high-velocity rinsing, reducing the number of modules needed and lowering manufacturing costs while maintaining effective dilution and rinsing performance.
Implementation Method 1
high-velocity rinsing
Implementation Method 2
effective dilution and rinsing performance
Data Source
AI summary
A method of washing fabric articles in a continuous batch tunnel washer, comprises providing a continuous batch tunnel washer having an interior, an intake, a discharge, and a plurality of modules that segment the interior. Fabric articles are moved from the intake to the discharge and through the modules in sequence. One or more modules define a wash zone for washing the fabric articles. One or more of the modules are rinse modules that have a perforated scoop. Some of the modules do not have a perforated scoop. After washing fabric articles, the fabric articles can be rinsed by counter flowing liquid in the washer interior at spaced apart modules and along a flow path that is generally opposite the direction of travel of the fabric articles from the intake to the discharge. Velocity rinsing can also replace a continuous counter flow. To improve rinsing and washing, one or more modules may be dilution zone modules, which receives a flow stream from the rinsing modules via a booster pump. A dilution zone module or drum preferably has a perforated scoop to drain the free water when transferring to the next dilution zone module or drum. Drums or modules without shells (carryover modules) have scoops for fabric article (e.g., linen) transfer with no perforations. Thus, the linen and all water go to the next downstream drum at the carryover modules.