Filter Press Retrofit Kit: Electric Actuation for Hydraulic Replacement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional filter presses rely on hydraulic systems for compression and transport, which are inefficient, environmentally harmful, and prone to contamination, with hydraulic oil usage being excessive and costly, and the mechanical challenges of hydraulic cylinders leading to slow cycle times and potential contamination of filter cakes.
Innovation Solution
A retrofitting kit that replaces hydraulic systems with an electrically operated compression and transport system using a planetary screw assembly and rack and pinion drive assembly, eliminating the need for hydraulic oil and allowing for faster and more efficient operation with adjustable speeds and reduced energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If hydraulic systems are used for compression and transport, then sufficient closing pressure and transport capability are achieved, but excessive hydraulic oil consumption occurs and environmental contamination risk increases
Solution Approach 1:
The patent replaces the hydraulic mechanical system with an electrical drive system. Electric motors directly drive the compression and transport mechanisms, eliminating the need for hydraulic oil entirely. This substitution resolves the contradiction by removing the substance consumption issue while maintaining system reliability through direct electrical actuation.
Solution Approach 2:
The patent extracts and removes the hydraulic system components (hydraulic cylinders, hydraulic oil reservoirs, pumps) from the filter press mechanism. By taking out the hydraulic subsystem entirely and replacing it with electrical motors and direct drive mechanisms, the patent eliminates hydraulic oil consumption while preserving the essential compression and transport functions.
2Productivity
If hydraulic cylinders are used for transport, then closing pressure is achieved, but cycle time increases and contamination risk to filter cakes increases
Solution Approach 1:
The patent substitutes hydraulic cylinders with electric motors that directly drive the transport and compression mechanisms. This eliminates the need for hydraulic fluid pathways that could leak and contaminate filter cakes. The electrical drive system also enables faster response times and more precise control, reducing cycle time while eliminating contamination risks.
Solution Approach 2:
The patent employs electric motors with direct drive mechanisms that eliminate the need for long piston rods and extensive hydraulic piping. The simplified mechanical structure reduces the surface area exposed to potential contamination sources, and the electrical system requires no consumable fluids that could leak and contaminate the product.
3Force
If hydraulic systems are used, then compression force is sufficient, but system complexity and cost increase
Solution Approach 1:
The patent replaces complex hydraulic systems (pumps, valves, cylinders, piping, reservoirs) with simpler electrical drive systems. Electric motors with direct or gear-driven mechanisms provide the necessary compression force without requiring extensive hydraulic infrastructure. This substitution reduces system complexity while maintaining sufficient closing force through direct electrical actuation.
Solution Approach 2:
The patent employs electric motors that can serve multiple functions - providing both transport motion and compression force through controlled operation modes. The same electrical drive system can deliver low-speed high-torque operation for compression or higher-speed operation for transport, eliminating the need for separate hydraulic systems for each function and thereby reducing overall system complexity.
4Power
If hydraulic oil is used for operation, then sufficient power is delivered, but environmental impact and handling requirements increase
Solution Approach 1:
The patent substitutes hydraulic power transmission with electrical power transmission. Electric motors convert electrical energy directly into mechanical motion, delivering the necessary power without requiring hydraulic oil as an energy transmission medium. This substitution eliminates environmental contamination risks associated with hydraulic oil leaks while maintaining full power delivery capability through electrical actuation.
Solution Approach 2:
The patent extracts and removes all hydraulic oil-related components from the system - reservoirs, pumps, cylinders, and piping. By taking out the hydraulic power transmission subsystem entirely and replacing it with electrical motors, the patent eliminates environmental hazards while preserving full operational power through direct electrical drive mechanisms.
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 electrically operated system significantly reduces cycle time, minimizes environmental impact, and enhances control and reliability, enabling faster and more efficient filter plate operation while reducing energy consumption and eliminating hydraulic oil-related issues.
Implementation Method 1
a compression system, coupled to the stationary support structure, the compression system comprising at least one electrically operated compression actuator comprising a planetary screw assembly
Implementation Method 2
a transport system coupled to the displaceable support structure, the transport system comprising at least one electrically operated transport actuator comprising a rack and pinion drive assembly
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The disclosure relates to a filter plate compression and transport retrofitting kit for a filter press, wherein the filter press comprises a stationary pressure plate, a displaceable pressure plate and a plurality of filter plates oriented perpendicular to a longitudinal dimension of the filter press, the retrofitting kit comprising: a stationary support structure configured to couple to the stationary pressure plate, a displaceable support structure configured to couple to the displaceable pressure plate, a compression system, coupled to the stationary support structure, the compression system comprising at least one electrically operated compression actuator comprising a planetary screw assembly, and a transport system coupled to the displaceable support structure, the transport system comprising at least one electrically operated transport actuator comprising a rack and pinion drive assembly, and wherein the compression system rigidly connects to the transport system so as to form, for each respective pair of compression actuators and transport actuators: a common actuator link which extends linearly from the stationary support structure to the displaceable support structure along the longitudinal dimension.