Wireless Sensor Integration in Wood Pressing for Steam Burst Prevention
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Solution Overview
Problem
Existing methods for producing wood-based material bodies, such as particle or fibreboards, face challenges in optimizing physical properties like strength due to variations in chip geometry, binding agents, and pressing parameters, leading to issues like steam bursting and inadequate hardening, which are difficult to monitor and control effectively with traditional measuring systems.
Innovation Solution
Integration of wireless, non-contact sensors within the material to measure and transmit actual values of physical state variables like pressure, temperature, and moisture, allowing real-time adjustment of pressing device parameters to achieve target values, thereby optimizing the production process and preventing steam bursting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional measuring systems with steel cannulas and miniature pressure sensors are used, then measurement data can be obtained, but the system becomes complex, requires precise handling, and is limited to plate thicknesses of usually a maximum of 10 mm
Solution Approach 1:
The patent replaces the mechanical measurement system (steel cannula, miniature pressure sensor, signal generator) with a wireless sensor system that uses electromagnetic fields for non-contact measurement. The sensor unit (5) with antenna (5a) transmits measurement data wirelessly to the evaluation device (6), eliminating the need for mechanical signal transmission through the material and removing the limitation on plate thickness.
2Measurement precision
If the signal generator is placed in the material to be pressed, then measurement data can be obtained, but the sensor must be removed again without damaging the material
Solution Approach 1:
The patent eliminates the need for sensor removal by using a wireless measurement system. The sensor unit (5) remains in the material throughout the process, and measurement data are transmitted wirelessly to the evaluation device (6) located outside the material. This avoids any mechanical intervention for sensor removal and prevents potential damage to the material.
3Manufacturing precision
If pressing parameters are not continuously monitored and adjusted, then the production process is simple, but physical properties like strength cannot be optimized and steam bursting may occur
Solution Approach 1:
The patent implements a feedback control system where the evaluation device (6) continuously receives measurement data from the sensor unit (5), compares actual values with target values, and triggers alerts or adjustments when deviations are detected. This enables continuous monitoring and optimization of pressing parameters to prevent steam bursting and ensure proper hardening.
Solution Approach 2:
The patent replaces complex mechanical measurement and manual adjustment systems with an automated wireless sensor and evaluation device system. The sensor unit (5) continuously measures physical state variables and transmits data wirelessly to the evaluation device (6), which automatically compares values and can trigger parameter adjustments, simplifying the overall control process while improving precision.
4Ease of manufacture
If too much moisture is present in the glued chips, then the material is easier to process, but steam pressure builds up excessively causing bursting
Solution Approach 1:
The patent uses the sensor unit (5) to continuously monitor moisture content and steam pressure during the pressing process. The evaluation device (6) receives real-time data, compares actual values with target values, and can trigger alerts or parameter adjustments when excessive moisture or steam pressure is detected, preventing bursting while maintaining ease of processing.
Solution Approach 2:
The patent replaces manual monitoring of moisture and pressure with an automated wireless sensor system. The sensor unit (5) continuously measures physical state variables including moisture content and steam pressure, transmitting data wirelessly to the evaluation device (6) for real-time analysis and control, enabling precise management of moisture to prevent bursting.
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 approach enables continuous monitoring and adjustment of pressing parameters, ensuring the production of wood-based material bodies with optimized physical properties, preventing bursting and ensuring proper hardening, while allowing the sensors to remain in the product and extending the applicability to thicker panels.
Implementation Method 1
Wireless, in particular non-contact sensors (5) integrated into the material to be pressed (4)
Implementation Method 2
a certain vapor pressure, also known as internal pressure, inevitably builds up in the pressing material due to the evaporating moisture
Implementation Method 3
the pressing temperature, ie the temperature prevailing during the pressing process to which the material to be pressed is exposed
Implementation Method 4
insufficient hardening of the binder and insufficient plasticization of the wood material can occur
Data Source
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AI summary
The invention relates to a method for producing a wood-based material body (1) in a device (2) comprising a pressing device (3), comprising the following steps: providing crushed wood material, in particular wood chips and/or fibers, forming the wood material into a pressing material (4) and pressing the pressing material (4) into a wood-based material body (1) in the pressing device (3).To optimize the physical properties of a wood-based material body, the invention proposes that, prior to the pressing step, at least one setpoint value for at least one physical state variable of the material being pressed (4) is stored, that at least one sensor (5) is integrated into the material being pressed (4), that the at least one sensor (5) determines at least one actual value for the at least one physical state variable, and that the at least one actual value is compared with the at least one setpoint value, wherein, based on the comparison of the actual and setpoint values, at least one parameter of the pressing device (3) can be controlled. Furthermore, the invention relates to a corresponding device (2) for producing a wood-based material body (1) and to a corresponding wood-based material body (1).