Horizontal Hotpress Thickness Control via Cylinder Feedback
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Solution Overview
Problem
The existing horizontal hotpress systems struggle to maintain the thickness of laminated boards within a specified range due to variations in wood material characteristics, leading to irregular products and increased production costs, as they rely solely on driven pressure without adequate control mechanisms.
Innovation Solution
A horizontal hotpress system incorporating an opening-closing cylinder and multiple press cylinders, with distance and pressure detecting means, allows for real-time thickness measurement and pressure control to maintain the boards' thickness within the allowable range, regardless of material type, by adjusting the operation distance and drive pressures of the press cylinders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a specified driven pressure is applied to hot-press boards, then the pressing process can be standardized, but the thickness of laminated boards cannot be maintained within specification due to material variations
Solution Approach 1:
The patent applies feedback control by using thickness detection means to measure the actual thickness of laminated boards during hot-pressing, and then adjusting the driven pressure of press cylinders based on this feedback. The control means modifies pressing parameters in real-time according to detected thickness values, ensuring thickness remains within specification despite material variations.
Solution Approach 2:
The patent implements dynamic adjustment of pressing parameters by allowing the driven pressure and operation distance of press cylinders to vary during the hot-pressing process based on real-time thickness detection. This dynamic control enables the system to adapt to material variations (hard/soft boards, different tree species, production areas) while maintaining standardized operation through automated adjustments.
2Manufacturing precision
If different pressing parameters are set for different board materials, then thickness specification can be maintained, but operation complexity and knowledge requirements increase significantly
Solution Approach 1:
The patent implements self-service operation by enabling the hot-pressing system to automatically detect board thickness and adjust pressing parameters without operator intervention. The detection means and control means work together to self-regulate the pressing process, eliminating the need for operators to possess specialized knowledge about different tree species, production areas, or material characteristics.
Solution Approach 2:
The patent automatically changes pressing parameters (driven pressure, operation distance) based on real-time thickness detection rather than requiring manual parameter selection based on material type. The control means adjusts these parameters dynamically, transforming a complex material-dependent parameter setting process into a simple automated thickness-controlled process.
3Manufacturing precision
If manual adjustment of pressing parameters based on material knowledge is used, then some thickness control can be achieved, but production costs increase due to lower yield ratio
Solution Approach 1:
The patent uses feedback control to prevent production of out-of-specification boards by continuously monitoring thickness during hot-pressing and adjusting pressing parameters accordingly. This real-time feedback mechanism ensures that all produced boards meet thickness specifications, maximizing yield ratio by eliminating irregular products that would otherwise require rejection or rework.
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 system improves the yield ratio of laminated boards by ensuring consistent thickness, reducing the need for material-specific expertise and simplifying the hotpressing process, while preventing irregular products and lowering production costs.
Implementation Method 1
an opening-closing cylinder (180), disposed at a center region on pressing surfaces (141) of the press plates (140F, 140B), and opening and closing by moving the press plates (140F, 140B) closer and distanced
Implementation Method 2
a plurality of press cylinders (150L, 150R, 150LH, 150RH, 150LL, 150RL), disposed at a plurality of positions different from each other to the pressing surfaces (141) of the press plates (140F, 140B) in order to surround the opening-closing cylinder (180), and pressing the object-to-be-processed (W) from a superposition direction respectively by driving the press plates (140F, 140B)
Implementation Method 3
a distance detecting means (181) of detecting an operation distance of the opening-closing cylinder (180) in the superposition direction while a plurality of the press cylinders press the object-to-be-processed (W)
Implementation Method 4
a pressure detecting means (151L, 151R, 151LH, 151RH, 151LL, 151RL) of detecting at least one of driven pressures applied to a plurality of the press cylinders (150L, 150R, 150LH, 150RH, 150LL, 150RL) respectively
Data Source
AI summary
Two press cylinders are disposed at an equal interval at left and right having the opening-closing cylinder therebetween, so as to have the approximately same distance from the conveying reference plane as the opening-closing cylinder. The opening-closing cylinder comprises an opening-closing linear encoder, which detects a decreased amount of the entire thickness of the object-to-be-processed as a displacement of the ram, when the object-to-be-processed is hot-pressed. The respective press cylinders comprise pressure sensors for press cylinders detecting pressing pressures of the pressing plates as cylinder inner pressures. A horizontal hotpress system is provided, which can easily improve yield ratio of the boards after hot-pressing by measuring thickness size of the object-to-be-processed while hot-pressed, according to an operation distance of the opening-closing cylinder, comprising an opening-closing cylinder for opening and closing the press plates, other than a plurality of the press cylinders for pressing the press plates.