Tunnel Washer Dual-Use Modules for Reduced Water Consumption
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Solution Overview
Problem
Continuous batch tunnel washers face inefficiencies due to constant counterflow during the main wash module, which dilutes washing chemicals and reduces their effectiveness, and require separate wash and rinse modules, increasing water consumption and operational complexity.
Innovation Solution
Implementing dual-use modules that function as both wash and rinse zones with interrupted counterflow, allowing a standing bath for chemical equilibrium and high-velocity counterflow rinsing, reducing water consumption and module count, and using recirculation pumps to minimize fresh water usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If constant counterflow is used during main wash module, then rinsing function is provided, but washing chemical effectiveness is reduced due to dilution
Solution Approach 1:
The system implements periodic action by alternating between wash mode and rinse mode in the same module. During wash mode, the module functions as a standing bath with no counterflow to maintain chemical concentration. During rinse mode, counterflow is activated for rinsing. This periodic switching allows the module to perform both washing and rinsing functions sequentially, resolving the contradiction between water consumption and chemical effectiveness.
Solution Approach 2:
The system applies dynamics by making the module's function changeable over time. The module can dynamically switch between being a wash module and a rinse module based on the operational phase. This dynamic functionality allows the same physical space to serve different purposes at different times, eliminating the need for separate dedicated wash and rinse modules while maintaining washing chemical effectiveness during the wash phase.
2Reliability
If separate wash and rinse modules are used, then washing and rinsing functions are dedicated, but water consumption and operational complexity increase
Solution Approach 1:
The system implements universality by designing modules that can perform multiple functions. Each module is capable of functioning as both a wash module and a rinse module depending on the operational phase. This multi-functionality eliminates the need for separate dedicated wash and rinse modules, reducing the overall module count and operational complexity while maintaining reliable washing and rinsing functions through temporal separation.
Solution Approach 2:
The system merges the wash and rinse functions into a single module by combining them in the same physical space but separating them in time. The module first performs washing as a standing bath, then performs rinsing with counterflow in the same module. This merging approach reduces the number of modules required while ensuring both functions are properly executed through sequential operation.
3Reliability
If multiple dedicated modules are used, then functional separation is achieved, but throughput efficiency decreases
Solution Approach 1:
The system uses periodic action to alternate between wash and rinse phases in the same module, allowing continuous processing flow. While one module is in rinse mode, another can be in wash mode, creating a continuous throughput stream. This periodic switching maintains functional separation in time while improving overall system throughput by eliminating idle time between modules.
Solution Approach 2:
The system ensures continuity of useful action by having modules continuously cycle between wash and rinse phases. There are no idle periods where modules are non-functional, as each module is constantly performing either washing or rinsing. This continuous operation maximizes productivity and throughput while maintaining proper functional separation through temporal sequencing.
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
Achieves low water consumption, increased throughput, and efficient soil removal with reduced module count, maintaining chemical effectiveness and improving rinsing efficiency through controlled water flow and high-velocity counterflow.
Implementation Method 1
The counter flow is along a path that is generally opposite the direction of travel of the fabric articles
Implementation Method 2
After a final module, fabric articles are then transferred to a liquid extraction device (e.g., press or centrifuge) that removes excess water
Implementation Method 3
After a final module, fabric articles are then transferred to a liquid extraction device (e.g., press or centrifuge) that removes excess water
Data Source
AI summary
A method of washing fabric articles in a tunnel washer includes moving the fabric articles from the intake of the washer to the discharge of the washer through first and second sectors that are a pre-wash zone. Liquid can be counter flowed in the wash interior along a flow path that is generally opposite the direction of travel of the fabric articles. The main wash zone can be heated as an option. In the wash zone, there is a pre-rinse and/or a rinse. The fabric articles are transferred to a water extraction device that enables removal of excess water. A sour solution can be added to the fabric articles while extracting excess water.