Modular Triple-Pass Tunnel Finisher for Expandable Fabric Throughput
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Solution Overview
Problem
Conventional tunnel finishers require large initial capacity to handle production levels and are not easily expandable to accommodate increased production, leading to the need for frequent and costly upgrades when production levels rise.
Innovation Solution
A triple pass tunnel finisher design featuring a full-length steam injection chamber and two separate hot air chambers, with modular components allowing for incremental expansion by inserting additional modules, enhancing dwell time and production capacity without the need for new equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional tunnel finishers are designed with large initial capacity to handle production levels, then current production needs are met, but the device cannot be easily expanded when production levels increase
Solution Approach 1:
The tunnel finisher is divided into multiple modular sections (steam injection chamber, first hot air chamber, U-shaped intermediate hot air chamber, second hot air chamber) that can be independently configured and expanded. Each module contains complete functional elements, allowing the system to be segmented into manageable units that can be added or removed based on production requirements.
Solution Approach 2:
The system incorporates adjustable conveyor speeds and variable dwell times that can be dynamically modified to accommodate different production levels. The modular design allows the physical configuration to be dynamically changed by adding or removing expansion modules between the front and rear modules.
2Reliability
If dwell time is increased to permit complete moisture evaporation, then garment finishing quality improves, but processing time increases
Solution Approach 1:
The drying process is segmented into multiple distinct hot air chambers (first hot air chamber, U-shaped intermediate hot air chamber, second hot air chamber) that operate in sequence. This segmentation allows each chamber to contribute partially to the drying process, achieving complete moisture evaporation through cumulative effect rather than requiring excessively long dwell time in a single chamber.
Solution Approach 2:
The U-shaped intermediate hot air chamber introduces a curved path that increases the effective drying length without proportionally increasing the linear footprint. The U-shaped configuration allows the garment to traverse a longer distance through the hot air environment, enhancing moisture evaporation efficiency while managing space utilization.
3Productivity
If conventional tunnel finishers include all functioning elements in a single cabinet, then the device is compact, but it cannot accommodate production increases without purchasing new equipment
Solution Approach 1:
The complete tunnel finisher system is segmented into front module, rear module, and expandable intermediate sections. Each module contains necessary functioning elements (heating apparatus, steam injection, hot air chambers), allowing the system to be configured in different sizes by varying the number of expansion modules while maintaining functional completeness.
Solution Approach 2:
The expansion modules are designed as universal components that can be inserted between the front and rear modules to provide additional drying capacity. These modules contain complete functional elements and can be added in increments, allowing a single base configuration to serve multiple production levels through modular expansion rather than requiring entirely different equipment.
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 triple pass tunnel finisher provides increased dwell time for effective moisture evaporation and expanded production capacity at a lower cost, allowing for flexible and cost-effective upgrades to meet changing production needs.
Implementation Method 1
a steam injection chamber downstream of the entrance for treating the fabric piece with steam
Implementation Method 2
In the hot air zone, the garment is heated and agitated with hot air to evaporate moisture from the garment
Implementation Method 3
the garment is heated and agitated with hot air
Implementation Method 4
a heating apparatus for heating the fabric piece
Data Source
AI summary
A triple pass tunnel finisher for finishing fabric. The finisher includes a side module, a front module, and a rear module. The side module includes an entrance for receiving a fabric piece to be conveyed through the apparatus, and a steam injection chamber downstream of the entrance for treating the fabric piece with steam. The front module communicates with the side module to receive the fabric piece conveyed therefrom, and includes first and second hot air chambers, and an exit downstream of the second hot air chamber. The rear module communicates with the front module to receive the fabric piece therefrom, and includes a heating apparatus for heating the fabric piece, and a U-shaped intermediate hot air chamber downstream from the first hot air chamber and upstream from the second hot air chamber for receiving the fabric piece from the first hot air chamber and for delivering the fabric piece to the second hot air chamber.