Filter Press Plate Handling for Fast Automated Maintenance
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Solution Overview
Problem
Existing filter presses face challenges such as prolonged downtimes, complex maintenance operations, limited dimensions, slow filtration processes, ineffective cake detachment, and inefficient washing systems, particularly in high-volume slurry dehydration applications like mining, leading to increased costs and reduced productivity.
Innovation Solution
A filter press design featuring a support structure with movable filtering plates, a robotized equipped group for automated plate/web replacement, a shaking system for efficient cake detachment, and a double supply system, allowing for a high number of plates and rapid operation without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual replacement of filtering plates is used, then maintenance can be performed, but machine stoppage time increases and operator safety is at risk
Solution Approach 1:
The filter press system performs self-maintenance through automated detection and replacement of filtering plates. The robotized end effectors autonomously remove defective plates and install new ones without human intervention, allowing the system to service itself during minimal stoppage time.
Solution Approach 2:
Manual mechanical operations by operators are replaced with an automated robotic system. The robotized end effectors use mechanical grippers to handle filtering plates, substituting human hands and tools with automated mechanical actuators controlled by a PLC, thereby eliminating safety risks and reducing maintenance time.
2Ease of operation
If a motorized carriage acts on the movable end head to move filtering plates, then plate movement is achieved, but the number of filtering plates is limited due to difficulty in complete opening
Solution Approach 1:
The filter press is divided into multiple independently controllable segments or groups of filtering plates. Instead of moving all plates simultaneously through a single carriage, the system can segment the plate pack and move different groups independently, enabling complete opening even with a large total number of plates.
Solution Approach 2:
The system transitions from static, fixed-position plate handling to dynamic, programmable plate movement. The PLC controller enables flexible positioning and movement of filtering plates in sequences, allowing the system to adapt to varying numbers of plates and optimize the opening/closing process for maximum productivity.
3Productivity
If rainfall type washing system is used, then all plates are washed, but the entire structure including mechanisms is sprayed causing deterioration
Solution Approach 1:
The washing system applies water locally and selectively to specific areas that require cleaning, rather than spraying the entire structure uniformly. targeted washing zones are defined to cover the filtering plates and webs while excluding sensitive mechanical components, thereby maintaining washing effectiveness while preventing corrosive damage to mechanisms.
Solution Approach 2:
The system uses removable shields or deflectors as intermediary elements between the washing water and the mechanical mechanisms. These intermediaries redirect water flow away from sensitive components while allowing full coverage of the filtering surfaces, protecting mechanisms from corrosive salts in the washing water.
4Ease of operation
If filtering plates are moved away gradually by movable end head, then opening is achieved, but the process is slow and productivity is reduced
Solution Approach 1:
The plate opening process uses periodic, staged motion rather than continuous gradual movement. The system moves plates in rapid sequences with brief pauses for positioning, creating a rhythmic opening pattern that increases overall speed while maintaining control and preventing plate damage.
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
Minimizes downtimes, enhances productivity, reduces maintenance risks and costs, and enables larger scale operations with efficient filtration and washing, ensuring high hourly throughput and operational availability.
Implementation Method 1
clamped in a pack by a hydraulic thrustor
Implementation Method 2
The slurry is pumped at high pressures inside these filtration chambers
Implementation Method 3
the plates are shaken in order to promote the detachment or the falling of the cakes of dehydrated slurry by gravitational force
Implementation Method 4
the liquid phase, which can pass through the filtering webs, is discharged from the filter press through drainage channels
Data Source
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Figure 3
AI summary
An improved filter press comprises a support structure (12) which extends in a longitudinal direction (X-X), a group (13) of filtering plates (18) which are provided with filtering webs and which are mounted on the support structure (12) and which are movable in the longitudinal direction (X-X) from an open configuration, in which some or all of the filtering plates (18) are spaced apart from each other, to a closed configuration, in which the filtering plates (18) are all clamped in a pack, and an equipped movable group (24) which is mounted in a movable manner in the longitudinal direction (X-X) on the support structure (12). The equipped movable group (24) comprises at least one lifting device (34, 36) for selectively lifting a filtering plate (18) or a filtering web and so as to remove it from the group (13) of filtering plates.