Fabric cleaning systems and methods using synchronized cross-machine direction traversing cleaning heads
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Solution Overview
Problem
Current fabric cleaning systems in industrial applications, such as papermaking and tissue manufacturing, are inefficient and economically wasteful due to high water and energy consumption, as well as excessive use of cleaning chemicals and fabric replacement.
Innovation Solution
A dual-beam, traversing shower cleaning system with synchronized cleaning heads on opposite sides of the fabric, utilizing high-pressure fluid application and vacuum to simultaneously clean both the sheet and roll sides, reducing the need for conventional drying systems and optimizing fabric life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional full-width cleaning systems are used, then complete fabric coverage is achieved, but water and energy consumption increases significantly
Solution Approach 1:
The cleaning system is divided into multiple independent cleaning zones along the fabric path, with each zone having its own cleaning head that can be independently controlled. This segmentation allows cleaning to be applied only where needed rather than across the entire fabric width continuously, reducing water and energy consumption while maintaining cleaning effectiveness.
Solution Approach 2:
The cleaning heads are made movable and can be dynamically positioned along the fabric width and activated only when required. The system uses sensors and controllers to adjust the position and operation of cleaning heads in real-time, enabling dynamic response to actual cleaning needs rather than continuous full-width operation.
2Reliability
If continuous full-width cleaning is applied, then fabric cleanliness is maintained, but cleaning chemistry consumption increases
Solution Approach 1:
Instead of continuous cleaning chemistry application, the system uses periodic cleaning cycles where chemistry is applied only when contamination is detected or at predetermined intervals. The cleaning heads can be activated intermittently based on actual fabric condition, reducing chemistry consumption while maintaining cleanliness standards.
Solution Approach 2:
The system applies cleaning chemistry locally only to specific contaminated areas of the fabric rather than uniformly across the entire fabric width. This targeted application is achieved through localized cleaning heads that can be positioned precisely where needed, reducing overall chemistry consumption while maintaining effective cleaning.
3Reliability
If conventional cleaning systems are used, then fabric surface cleaning is achieved, but fabric lifespan is reduced due to excessive handling and replacement
Solution Approach 1:
The cleaning system is designed to maintain fabric condition proactively, allowing the fabric to continue serving its function for longer periods between cleanings or replacements. By using gentle, targeted cleaning methods and reducing unnecessary fabric handling, the system extends fabric service life while maintaining cleaning effectiveness.
Solution Approach 2:
The system performs preliminary cleaning actions to prevent contamination buildup that would require more aggressive cleaning or fabric replacement later. By maintaining fabric cleanliness through gentle, regular cleaning, the system prevents conditions that would lead to fabric degradation and premature replacement.
4Productivity
If synchronized dual-beam traversing cleaning heads are implemented, then cleaning efficiency is improved, but device complexity increases
Solution Approach 1:
The system combines multiple cleaning functions into integrated cleaning head assemblies that perform multiple operations simultaneously. The dual-beam traversing heads combine cleaning, drying, and inspection functions in unified modules, improving productivity while managing complexity through functional integration rather than separate systems.
Solution Approach 2:
The cleaning heads are designed as multi-functional units that can perform various cleaning operations and adapt to different fabric types and contamination levels. This universality allows a single system design to handle multiple cleaning scenarios, improving overall productivity while avoiding the need for multiple specialized systems that would increase complexity.
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 approach significantly reduces water and energy usage, minimizes cleaning chemistry consumption, and extends fabric lifespan by ensuring thorough cleaning and drying, thereby enhancing operational efficiency and reducing resource expenditure.
Implementation Method 1
vacuum suction boxes 17, 18
Implementation Method 2
high-pressure shower 15 on the sheet side, the high pressure shower 16 on the non-sheet side
Data Source
AI summary
A fabric cleaning system is disclosed that includes first and second cleaning heads on opposite sides of a fabric that travels along a machine direction, each of the first and second cleaning heads being mounted on first and second beams that extend along a cross-machine direction, and each of the first and second cleaning heads being traversable along the respective first and second beams.