Impact of Main Frame Structure Design on Stability
The water extraction press is the core component of tunnel washer systems. If the press fails, the entire system halts, making its role in the tunnel washer system crucial with high technical requirements. The stability of the press can be assessed from several aspects: 1) main frame structure design; 2) hydraulic system; 3) cylinder quality; 4) pressing basket and bladder technology and quality.
Main Frame Structure Design of the Water Extraction Press
Today let’s talk about the main frame structure design of the press. Currently, there are two main types of water extraction presses on the market: heavy-duty and lightweight. These types differ significantly in structure and performance.
1. Lightweight Structure Press
The lightweight water extraction press is supported by four cylindrical steel rods, each made from 80-mm-diameter steel. These rods are machined and assembled with nuts and bottom plates. While this design is cost-effective, it presents several challenges:
Precision Assembly Requirements: The assembly process for lightweight presses demands high precision. Any deviation can affect the overall stability and performance of the press.
Durability Concerns: The 80mm diameter steel rods may reduce to 60mm after machining, making them susceptible to cracks and fractures over time. The high-intensity use in washing facilities exacerbates this issue, leading to potential failures.
Complex Replacement Process: When a pillar breaks, it requires full disassembly and reassembly, which can be time-consuming. This downtime can disrupt operations and impact the facility’s productivity. Cases in China have shown that repairs can range from several days to a month, with lightweight presses generally having a lifespan of 8–10 years.
2. Heavy-Duty Structure Press
In contrast, the heavy-duty water extraction press features a robust frame constructed from 200-mm-thick special steel plates. These plates are hollowed out to form a 200mm*200mm frame. This design provides several advantages:
Enhanced Durability: The heavy-duty structure can withstand long-term, high-intensity use without deforming or fracturing. This robustness contributes to a longer operational life.
Extended Lifespan: With proper maintenance, heavy-duty presses can last 20 years or more, making them a more durable investment compared to lightweight presses.
Simplified Maintenance: The design of heavy-duty presses allows for easier maintenance and repairs, minimizing downtime and operational disruptions.
Improved Dewatering Efficiency: Heavy-duty presses typically offer higher dewatering efficiency. For instance, CLM’s heavy-duty press is designed to handle pressures up to 63 bar, with actual usage around 48 bar. This results in a towel water content of about 50%. In comparison, lightweight presses usually operate at pressures below 40 bar, leading to higher water content and increased drying costs.
Operational Efficiency and Cost Implications
The choice between heavy-duty and lightweight presses has significant implications for operational efficiency and cost. Heavy-duty presses, with their superior durability and dewatering capabilities, can lead to cost savings over the long term. Facilities that use heavy-duty presses often experience reduced drying times and lower energy costs, contributing to overall operational efficiency.
Conclusion
Choosing the right water extraction press is crucial for the success of tunnel washer systems. Understanding the differences between heavy-duty and lightweight presses can help facilities make informed decisions impacting operational efficiency, maintenance requirements, and long-term costs. By investing in robust equipment and paying attention to design details, facilities can ensure stable and efficient operations, minimizing downtime and maximizing performance.
Post time: Aug-07-2024