Multi-Station Pulp Forming Equipment Parallel Drying
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Solution Overview
Problem
Traditional automatic pulp forming technologies have inefficiencies due to long drying times and require significant labor, with prior solutions failing to optimize the combination of multiple drying stations with a single forming station for waste-paper-based packaging production.
Innovation Solution
An automatic multi-station integrated equipment system that includes a suction filter forming station and multiple high-temperature drying stations, utilizing a forming frame, pulp tank, forming plate apparatus, and transfer plate apparatus with air supply systems, allowing for continuous pulp processing and reduced labor requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional suction filter forming station is used with single drying station, then equipment structure is simple, but drying time is long and machine efficiency is low
Solution Approach 1:
The drying function is segmented into multiple independent drying stations (first drying station, second drying station, third drying station) that operate in parallel. Each drying station has its own drying chamber and heating elements, allowing simultaneous processing of multiple products and eliminating the idle time that occurs in single-station systems.
Solution Approach 2:
Multiple drying stations are merged with a single suction filter forming station to create an integrated production line. The forming station feeds wet-formed products to multiple drying stations, which work concurrently to dry different products or different sides of products, maximizing the utilization of the forming station and dramatically improving overall productivity.
2Productivity
If traditional forming and drying system is used, then equipment operation is simple, but labor requirements are high and unit output per labor is low
Solution Approach 1:
The system maintains continuous operation by having multiple drying stations work in parallel while the forming station continuously produces wet-formed products. Transfer mechanisms ensure continuous movement of products between forming and drying stations, eliminating idle time and maximizing output per labor hour.
Solution Approach 2:
The multi-station system is designed to operate with minimal human intervention. Automated transfer mechanisms move products between stations, and the system can maintain continuous operation with only one operator per machine per shift, as the equipment serves itself through automated processes.
3Productivity
If forming station completes cycle in less than 5 seconds but drying takes substantially longer, then forming speed is high, but drying becomes the bottleneck reducing overall productivity
Solution Approach 1:
The drying process is segmented across multiple independent stations that can operate simultaneously. While one product is being dried in the first drying station, another product can be dried in the second drying station, and a third in the third drying station, effectively parallelizing the drying function to match the high-speed forming capability.
Solution Approach 2:
The system uses periodic action by cycling products through different drying stations in a coordinated manner. As products complete drying in one station, they are automatically transferred to the next station or to discharge, creating a continuous periodic flow that matches the forming station's cycle rate and eliminates drying as a bottleneck.
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 enhances machine efficiency, reduces raw material usage, improves product quality and stability, and decreases labor needs by enabling continuous operation with one worker managing multiple output stations.
Implementation Method 1
suction filter forming station
Implementation Method 2
high-temperature drying stations
Data Source
AI summary
Disclosed are embodiments of an automatic multi-station integrated equipment for forming waste-paper-based-pulp packaging products, and related methods of operation. The equipment comprises at least one suction filter forming station integrated with one or more pair of high-temperature drying stations. The suction filter forming station includes a forming frame, pulp tank, forming plate apparatus, transfer plate apparatus, transfer air storage tank, horizontal transfer air cylinder, vertical transfer air cylinder, forming hydraulic cylinder, and forming apparatus main shaft. Each high-temperature drying station may include an upper press plate apparatus, lower press plate apparatus, high pressure air cylinder, lower horizontal air cylinder, air storage tank and upper horizontal air cylinder. Embodiments of the invention generally use one suction filtration forming station in conjunction with multiple high temperature drying stations to form a single production line.