Embedded Electrode Detection for Gypsum Board Forming Plates
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Solution Overview
Problem
The increasing production speed and reduced tension and thickness of lining paper sheets in gypsum board production lead to frequent tears and production stoppages due to foreign bodies caught between forming plates, causing defects and disrupting continuous production.
Innovation Solution
Embedding an electrically conductive electrode within the forming plates, insulated from the plate surface, to detect paper cuts and automatically expand the space between plates, allowing foreign bodies to pass and preventing further damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the production speed is increased and the lining paper sheet thickness is reduced, then the productivity is improved, but the lining paper sheet becomes more prone to tearing when foreign bodies are caught between forming plates
Solution Approach 1:
The patent applies preliminary action by detecting the cut of the lining paper sheet before foreign bodies cause continuous damage. The detection device identifies paper cuts early, triggering the space expansion mechanism proactively to remove foreign bodies before they can tear the paper completely and stop production.
Solution Approach 2:
The patent converts the harmful effect of foreign bodies caught between forming plates into a beneficial automatic detection and response system. When foreign bodies cause paper cuts, the detection device utilizes this event to trigger space expansion, automatically removing the foreign bodies and preventing further damage, thus turning a production problem into an automated quality control mechanism.
2Reliability
If foreign bodies are caught between forming plates, then the lining paper sheet is cut and production stops, but removing foreign bodies requires complicated manual operations
Solution Approach 1:
The patent implements self-service by creating an automated system where the detection device and space expansion mechanism work together without manual intervention. When foreign bodies are detected through paper cut detection, the system automatically expands the space between forming plates to remove the foreign bodies and restores production, eliminating the need for complicated manual removal operations.
Solution Approach 2:
The patent applies feedback by using the detection device to monitor the condition of the lining paper sheet continuously. When a cut is detected, this feedback triggers the space expansion mechanism, which automatically removes foreign bodies. The system continuously monitors and adjusts based on the detected conditions, maintaining continuous production without manual intervention.
3Productivity
If the space between forming plates is expanded to remove foreign bodies, then production can continue, but the detection method using external electrodes arranged downstream has limitations
Solution Approach 1:
The patent applies preliminary action by positioning the detection device to detect paper cuts at the optimal location before foreign bodies cause complete paper failure. The detection device is arranged to identify cuts early in the process, triggering space expansion proactively to remove foreign bodies before they can completely tear the paper and stop production.
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
Enables continuous production of gypsum boards at high speeds with reduced paper tension and thickness without stopping, reducing defective products and maintaining production flow by detecting and addressing paper cuts and foreign bodies effectively.
Implementation Method 1
when the lining paper sheet is cut to bring the plate main body and the embedded electrode into contact with the gypsum slurry and an electric current flows in the circuit
Data Source
AI summary
As a lower forming plate 8, a forming plate having: a lower plate main body 10 constituted from an electrically conductive material; and a lower embedded electrode 12 embedded in the lower plate main body 10, the lower embedded electrode 12 being electrically insulated from the lower plate main body 10 by an insulator 14 and being embedded so as for a portion thereof to be exposed on the surface of the lower plate main body 10 making contact with a lower lining paper sheet 16 is used.