Tunnel Washer Conductivity Control for Counterflow Rinsing
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Solution Overview
Problem
Commercial continuous batch tunnel washers face issues with water conductivity exceeding preset limits, leading to linen sticking to ironing implements due to improper rinsing, which affects the effectiveness of washing chemicals and the ironing process.
Innovation Solution
The implementation of conductivity sensors in multiple modules of the tunnel washer, including the press tank and pulse flow tank, to monitor and adjust water conductivity by introducing fresh water during a 'pulse flow' or higher velocity flow, ensuring the conductivity remains within a pre-selected range, and using an 'empty pocket' module to rapidly clear excessive conductivity by diverting water to a sewer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If water is used for pressing without conductivity control, then the pressing process can proceed, but the water conductivity exceeds preset limits causing linen to stick to ironing implements
Solution Approach 1:
The system employs conductivity sensors that continuously monitor water conductivity in the press tank and pulse flow tank. When conductivity exceeds preset limits, the control system automatically activates fresh water introduction valves to adjust conductivity back to acceptable ranges, creating a closed-loop feedback control mechanism that prevents linen sticking while maintaining pressing operations
Solution Approach 2:
The system dynamically adjusts water conductivity parameters by introducing fresh water when conductivity exceeds limits. The conductivity setpoint and acceptable range are programmable, allowing flexible parameter management to prevent linen sticking while maintaining pressing productivity
2Object-affected harmful factors
If conductivity sensors and control systems are added to monitor and adjust water conductivity, then linen sticking is prevented, but the device complexity increases
Solution Approach 1:
The system is designed to automatically monitor conductivity and self-correct by introducing fresh water when needed, without requiring manual intervention. The control system autonomously manages conductivity levels, reducing the need for complex manual monitoring and adjustment procedures while preventing linen sticking
Solution Approach 2:
The conductivity control system serves multiple functions: it monitors conductivity in both press tank and pulse flow tank, automatically adjusts conductivity levels, and prevents linen sticking. This multi-functional approach consolidates monitoring and control tasks into a single integrated system, reducing overall complexity compared to separate systems for each function
3Object-affected harmful factors
If fresh water is introduced during pulse flow to correct conductivity, then conductivity is maintained within acceptable range, but the time required to correct conductivity errors increases
Solution Approach 1:
The system introduces fresh water during the pulse flow phase, which occurs before the pressing operation. This preliminary correction ensures that conductivity is adjusted to acceptable levels before linen is pressed, preventing sticking issues without requiring time loss during the actual pressing operation
Solution Approach 2:
The system uses periodic pulse flow phases to introduce fresh water and correct conductivity. By utilizing these periodic intervals for conductivity adjustment, the system maintains continuous monitoring and correction capability without requiring extended correction times, as corrections are performed during naturally occurring pulse flow cycles
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 solution effectively maintains water conductivity within an acceptable range, reducing the time required to correct conductivity errors by 40-50% and preventing linen from sticking to ironing implements, thereby enhancing the washing and ironing process efficiency.
Implementation Method 1
one or more modules have conductivity sensors that monitor water conductivity
Implementation Method 2
Water is selectively transferred in order to maintain water conductivity to within a pre-selected acceptable range
Data Source
AI summary
A method of washing fabric articles in a tunnel washer that includes moving the fabric articles from the intake of the washer to the discharge of the washer and through multiple modules or sectors. Liquid can be counter flowed in the washer interior along a flow path that is generally opposite the direction of travel of the fabric articles in order to rinse the fabric articles. While counterflow rinsing, the flow rate can be maintained at a selected flow rate or flow pressure head. One or more booster pumps can optionally be employed to maintain constant counterflow rinsing flow rate or constant counterflow rinsing pressure head. A source of fresh, make-up water can be provided to adjust conductivity. Conductivity is monitored in at least one of the modules. Conductivity of fluid in the discharged fabric articles is monitored. Make up water is added to one or more modules before if the conductivity of water in the discharged fabric articles exceeds a threshold value. In one embodiment, one of the modules is an empty pocket that is drained of fluid when rinsing with counterflowing liquid.