Automated Molten Plastic Filter Belt Replacement
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Solution Overview
Problem
The existing filter apparatus for molten plastic material requires frequent manual replacement of filter elements, leading to high labor costs and operator stress, as the pressure increase often necessitates continuous operator intervention to maintain the filtration process.
Innovation Solution
An automated filter apparatus that uses a belt made of filtering material, which is automatically replaced when pressure exceeds a predetermined value, allowing for continuous operation with minimal human intervention by sliding the belt along different advancement directions to maintain unobstructed flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual filter element replacement is used, then the apparatus structure is simple, but labor time and operational cost increase significantly
Solution Approach 1:
The filter element is designed with movable contact ends that can automatically shift position along the filter channel. When the filter element becomes obstructed, the contact ends move to engage with a replacement filter element, enabling automatic replacement without manual intervention. This dynamic mechanism resolves the contradiction by automating the replacement process while maintaining relatively simple apparatus structure.
Solution Approach 2:
The filter element replacement system operates autonomously through self-service mechanisms. The movable contact ends automatically detect obstruction through pressure differential and initiate the replacement process by engaging with the replacement filter element stored in the repository. This eliminates the need for continuous operator presence and significantly reduces labor time while keeping the apparatus structure manageable.
2Reliability
If frequent filter replacement is required, then filtration effectiveness is maintained, but productivity decreases due to operational interruptions
Solution Approach 1:
A repository is provided that stores a replacement filter element in advance, positioned and ready for immediate installation. When the active filter element becomes obstructed, the system automatically retrieves and installs the pre-positioned replacement element without interrupting the molten plastic material flow. This preliminary preparation of replacement elements ensures continuous filtration effectiveness while maintaining uninterrupted productivity.
Solution Approach 2:
The filter element replacement mechanism is designed to occur without stopping the molten plastic material flow through the filter channel. The movable contact ends and replacement mechanism operate simultaneously with the continuous material flow, ensuring that filtration effectiveness is maintained while productivity is not compromised by operational interruptions.
3Extent of automation
If automated belt replacement is implemented, then labor requirements are reduced, but device complexity increases
Solution Approach 1:
The filter element is segmented into a fixed portion and movable contact ends. This segmentation allows the movable contact ends to independently move and engage with replacement elements, providing automated replacement functionality. The segmentation approach achieves automation while keeping each component relatively simple, thus resolving the contradiction between automation extent and device complexity.
Solution Approach 2:
The movable contact ends act as intermediaries between the active filter element and the replacement filter element. These contact ends automatically detect obstruction and facilitate the transfer from the obstructed filter element to the replacement element stored in the repository. This intermediary mechanism enables automated replacement while maintaining a relatively simple apparatus structure without requiring complex automated handling systems.
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 apparatus significantly reduces labor requirements, enabling reliable and efficient continuous filtration of molten plastic material by automating key operating steps, allowing for periodic operator involvement rather than continuous presence, thus lowering operational costs and stress.
Implementation Method 1
a belt (8) made of a filtering material for molten plastic materials... intercepting the flow of molten plastic material with the aim of retaining any solid impurities present in the molten plastic material
Implementation Method 2
pressure measuring means (not illustrated) arranged in the first stretch (3) of the relative at least a filter channel (2) included and activatable for automatically measuring the pressure of the first stretch (3)
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
A filter method and a filter apparatus of molten plastic material are described. The method comprises following steps: A) predisposing an infeed of molten plastic material; B) predisposing at least a filter channel in which an infed relative flow of molten plastic material is made to slide in a first direction; C) subdividing the at least a filter channel included into relative first and second stretches, arranged, respectively, upstream and downstream, with respect to the first advancement direction, the first stretch having a relative end arranged downstream and the second stretch having a relative end arranged upstream, with respect to the first advancement direction; D) automatically arranging, in the at least a filter channel included, a portion of a belt (8) made of a filtering material for molten plastic materials, in a relative filtering position in which it is in contact with the ends of the first and second stretch for intercepting the flow of molten plastic material and retaining any impurities; E) automatically measuring the pressure in the first stretch of the at least a filter channel included; F) automatically comparing a first predetermined reference pressure value with each pressure value measured in the preceding step for automatically replacing the portion of belt (8), causing the belt to automatically slide along a second advancement direction (D2) in such a way as to arrange a further unobstructed portion of the belt in the filtering position; G) reiterating steps E) and F).