A corn stalk axially partitioned progressive shredding mechanism and shredding method

Abstract

This invention belongs to the field of crop straw processing technology, and particularly relates to an axially partitioned progressive shredding mechanism and method for corn straw. It includes a frame, a power transmission assembly, a shredding chamber, and segmented cutter rollers. The shredding chamber is formed by an upper cover plate, a lower side plate, and large-angle toothed shredding plates, fine-toothed shredding plates, and arc-toothed shredding plates, sequentially divided along the material conveying direction into a feeding and guiding zone, a core shredding zone, and a polishing and discharging zone. The segmented cutter rollers are respectively equipped with double-bending hammers, single-bending hammers, and rectangular arc-toothed hammers corresponding to the three zones. A guide plate is provided on the inner side of the upper cover plate, and the hammers in each zone are arranged spirally. The shredding method includes four steps: power transmission, feeding and guiding, core shredding, and polishing and discharging. This invention extends the shredding path through axial partitioning and implements graded progressive shredding, solving problems such as easy entanglement and blockage, unstable shredding quality, and high energy consumption in existing shredding machines when processing high-moisture straw. It achieves full separation, uniform shredding, and low-energy continuous operation.

Description

Technical Field

[0001] This invention belongs to the field of crop straw treatment technology, and particularly relates to a corn straw axial partitioning progressive shredding mechanism and shredding method. Background Technology

[0002] Corn stalks are one of the most abundant crop straw resources in my country. Shredding is a crucial step in converting corn stalks into forage, requiring the whole stalk to be broken into soft, fibrous segments 10–180 mm in length and no more than 5 mm in width to improve palatability, digestibility, and feed value. In cold northern regions like Heilongjiang, corn stalks are generally in a high-moisture state during the autumn harvest, with high water content, strong fiber toughness, and a tendency to stick and tangle. Direct shredding without drying maximizes nutrient retention, reduces the risk of mold, and is suitable for forage conversion processes such as silage / micro-silage, making it an important technical pathway for utilizing corn stalks as feed in cold regions.

[0003] Currently, the mainstream straw shredding equipment is mainly the hammer mill, which relies on the impact, collision, and rubbing of high-speed rotating hammers to achieve crushing. It has the characteristics of simple structure and wide adaptability, and is the dominant machine type in straw forage processing in China. However, traditional hammer mills generally adopt a radial instantaneous shredding mode, in which straw is swept rapidly through a single shredding chamber in a radial direction. This has inherent defects such as short residence time, few impacts, and uneven load distribution, and poor adaptability to the working conditions of high-humidity straw in cold regions. In actual operation, this type of machine mainly has the following problems: high-humidity straw fibers are tough and easy to entangle, and frequent material blockage occurs during feeding, which seriously affects the continuity of operation; the short residence time of straw in the shredding chamber makes it difficult to complete sufficient dissociation within a limited time, resulting in insufficient shredding of some straw, while local areas are over-crushed due to concentrated impact loads, generating a large amount of dust and unstable shredding quality; the large ineffective impact load results in high energy consumption and makes it impossible to achieve quality and energy consumption coordination. Summary of the Invention

[0004] The purpose of this invention is to provide an axially partitioned progressive shredding mechanism and method for corn stalks, in order to solve the technical problems of existing radial hammer shredders when processing corn stalks in cold and humid regions. These problems arise because the stalks are swept radially through a single shredding chamber instantaneously, resulting in short residence time, few impacts, and uneven load distribution, leading to entanglement and blockage, insufficient shredding and excessive crushing, and high energy consumption.

[0005] To achieve the above objectives, the specific technical solution of the corn stalk axial partition progressive shredding mechanism and shredding method of the present invention is as follows: A corn stalk axially partitioned progressive shredding mechanism includes a frame, a power transmission assembly, a shredding chamber, and segmented cutter rollers. The power transmission assembly and the shredding chamber are both mounted on the frame, and the segmented cutter rollers are rotatably disposed within the shredding chamber. The power transmission assembly includes a driven pulley, a belt, a driving pulley, and a motor. The motor is fixedly mounted on the frame, the driving pulley is mounted on the output shaft end of the motor, the driven pulley is mounted on one end of the segmented cutter roller, and the driving pulley and the driven pulley are connected by belt drive. The kneading chamber is formed by an upper cover plate, a lower side plate, and a large-angle tooth kneading plate, a fine-tooth kneading plate, and a circular arc tooth kneading plate. The inlet end of the kneading chamber is provided with a feeding port, and the outlet end of the kneading chamber is provided with a discharge port. The segmented cutter roller includes a pin shaft and multiple hammer holder plates, a spun yarn shaft, hammer blade spacers, rectangular arc toothed hammer blades, single-bending hammer blades, and double-bending hammer blades. The two ends of the spun yarn shaft are rotatably supported on the frame through bearing seats. Multiple hammer holder plates are fixedly arranged along the axial direction of the spun yarn shaft. The pin shaft passes through each hammer holder plate. The hammer blade spacers are sleeved on the pin shaft and located between adjacent hammer holder plates. Multiple rectangular arc toothed hammer blades, single-bending hammer blades, and double-bending hammer blades are all set on the pin shaft and are axially positioned by the hammer blade spacers. Along the axial conveying direction of the material, the kneading chamber is sequentially divided into a feeding and guiding zone, a core kneading zone, and a polishing and discharging zone; the large-angle toothed kneading plate is set in the feeding and guiding zone, the fine-toothed kneading plate is set in the core kneading zone, and the arc-shaped toothed kneading plate is set in the polishing and discharging zone; the double-bending hammer is set in the feeding and guiding zone, the single-bending hammer is set in the core kneading zone, and the rectangular arc-shaped toothed hammer is set in the polishing and discharging zone. The inner side of the upper cover plate is uniformly distributed with guide plates along the axial direction. The double-bending hammer blades, single-bending hammer blades, and rectangular arc toothed hammer blades are spirally arranged along the circumference of the kneading shaft. During the rotation of the segmented cutter roller, the guide plates work together to push the material axially.

[0006] Furthermore, the working surface of the double-bending hammer is a three-dimensional composite curved surface, which is used to simultaneously realize the functions of straw hooking, preliminary kneading and axial pushing.

[0007] Furthermore, the tooth tip of the arc-shaped rubbing plate has an arc transition structure, which is used to polish the surface burrs of the filamentous straw in conjunction with the rectangular arc-shaped toothed hammer.

[0008] Furthermore, the guide plates are evenly distributed along the axial direction of the upper cover plate, and the hammers in each area work together with the guide plates during rotation to guide the material to flow directionally from the feeding and guiding area through the core kneading area to the polishing and discharging area along the axial direction.

[0009] A method for progressively shredding corn stalks in an axially partitioned manner using the aforementioned shredding mechanism includes the following steps: S1 power transmission steps: Start the motor, and through the transmission action of the driving pulley, belt and driven pulley, drive the skein shaft and segmented cutter roller to rotate at high speed; S2 Feeding and Guiding Steps: Corn stalks are fed into the feeding and guiding area of ​​the shredding chamber through the feeding port. The stalks are hooked by double-bending hammers. Under the combined action of the double-bending hammers and the large-angle toothed shredding plate, the stalks are initially loosened. At the same time, under the guiding action of the spirally arranged hammers and the guide plate, the stalks are pushed axially to the core shredding area. S3 Core Spunling Step: After the straw enters the core spunling zone, it is subjected to repeated loading of shearing, tearing and kneading under the combined action of the single bending hammer and the fine toothed kneading plate, so that the straw fibers are fully dissociated and spun into fibers. S4 Polishing and Discharging Steps: After filamentization, the straw enters the polishing and discharging area, where it is gently rubbed and polished under the combined action of rectangular arc-toothed hammers and arc-toothed rubbing plates, forming filamentous material. Under the centrifugal force generated by the rotation of segmented cutter rollers, the material is discharged from the discharge port.

[0010] Furthermore, throughout the shredding process, by extending the shredding path axially and controlling the material residence time, the high-moisture corn stalks are fully disintegrated and shredded uniformly without increasing the speed of the segmented cutter rollers or the impact load.

[0011] Furthermore, by differentiating the kneading intensity of the three zones—the feeding and guiding zone, the core kneading zone, and the polishing and discharging zone—the dissociation process of straw from whole stalks to filaments is matched.

[0012] The corn stalk axial partition progressive shredding mechanism and shredding method of the present invention have the following advantages: By sequentially setting up a feeding and guiding zone, a core shredding zone, and a polishing and discharging zone along the material conveying axis, corn stalks undergo three progressive processing stages: initial loosening, full fiber dissociation, and surface polishing. This effectively extends the effective shredding path and residence time of the stalks in the shredding chamber, achieving full fiber dissociation without increasing the speed of the cutter rollers. The three zones employ a differentiated shredding intensity design, with a gradual shredding pattern from weak to strong to gentle precisely matching the dissociation pattern of high-moisture stalks from whole plants to filaments. This avoids insufficient fiber dissociation due to insufficient shredding time and prevents excessive crushing and dust generation caused by concentrated local impact loads. It ensures that the length (10-180mm) and width (not greater than 5mm) of the finished filament material consistently meet feed standards, resulting in soft, palatable fibers. The consistency and stability of the shredding quality are significantly superior to traditional radial hammer mills.

[0013] Targeting the characteristics of corn stalks in cold, high-humidity regions—high moisture content, strong fiber toughness, and easy adhesion and entanglement—a double-bending hammer with a three-dimensional composite curved working surface is installed in the feeding and guiding zone. This hammer features functions such as stalk hooking, preliminary kneading, and axial pushing, solving the problem of entanglement and accumulation during material feeding. The guide plates evenly distributed axially along the inner side of the upper cover plate work in conjunction with the hammers arranged spirally in each area. During the rotation of the cutter roller, a continuous axial thrust is applied to the material, guiding the straw along a predetermined axial path from the feeding and guiding zone through the core kneading zone to the polishing and discharge zone. This avoids disordered movement and circumferential accumulation of material within the kneading chamber, solving the frequent material blockage problem encountered by traditional models when processing high-moisture corn stalks, and improving operational continuity and reliability.

[0014] Abandoning the traditional radial shredder's energy-consuming mode of relying on increased impact load for enhanced crushing, this new machine extends the shredding path axially and uses zoned progressive loading. This allows the straw to receive shredding action sequentially along the longer shredding path, matching its current dissociation state. The load is distributed differentially along the axial direction, avoiding localized overload and significant ineffective impact energy consumption caused by concentrated load in a single chamber, as seen in traditional models. The zoned variable load loading method ensures that energy input precisely matches the actual crushing requirements of the material, reducing ineffective impact energy consumption.

[0015] Adopting a modular design, the machine features a compact and high-strength structure. It can be used as a fixed unit for on-site forage preparation in livestock farms, or installed on a mobile platform for on-site processing of high-moisture straw in the field, reducing straw transportation costs and storage losses. The hammers and kneading plates in each functional area can be independently disassembled and replaced, making maintenance convenient. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 For the present invention Figure 1 Schematic diagram of the AA section structure; Figure 3 This is a top view of the structure of the present invention; Figure 4 For the present invention Figure 2 Schematic diagram of the BB section structure; Figure 5 For the present invention Figure 4 Enlarged view of region A in the middle; Figure 6 For the present invention Figure 4 Enlarged view of region B in the middle; Figure 7 For the present invention Figure 4 Enlarged diagram of region C in the middle; Figure 8 This is a schematic diagram of the bearing housing mounting structure of the present invention; The markings in the diagram are as follows: 1. Frame; 2. Feed port; 3. Top cover plate; 4. Driven pulley; 5. Belt; 6. Drive pulley; 7. Motor; 8. Pin; 9. Hammer holder plate; 10. Kneading shaft; 11. Discharge port; 12. Bearing seat; 13. Lower side plate; 14. Guide plate; 15. Hammer blade spacer; 16. Large angle toothed kneading blade; 17. Fine toothed kneading blade; 18. Arc toothed kneading blade; 19. Rectangular arc toothed hammer blade; 20. Single bending hammer blade; 21. Double bending hammer blade. Detailed Implementation

[0017] To better understand the purpose, structure, and function of this invention, the following detailed description of a corn stalk axial partition progressive shredding mechanism and shredding method, in conjunction with the accompanying drawings, is provided.

[0018] like Figure 1-8 As shown, the present invention discloses a corn stalk axial partition progressive shredding mechanism and shredding method, including a frame 1, a power transmission component, a shredding chamber and a segmented cutter roller. The power transmission component and the shredding chamber are both installed on the frame 1, and the segmented cutter roller is rotatably disposed in the shredding chamber. The power transmission assembly includes a driven pulley 4, a belt 5, a driving pulley 6 and a motor 7. The motor 7 is fixedly mounted on the frame 1, the driving pulley 6 is mounted on the output shaft end of the motor 7, the driven pulley 4 is mounted on one end of the segmented cutter roller, and the driving pulley 6 and the driven pulley 4 are connected by the belt 5. The kneading chamber is formed by an upper cover plate 3, a lower side plate 13, a large-angle tooth kneading plate 16, a fine-tooth kneading plate 17, and a circular arc tooth kneading plate 18. The inlet end of the kneading chamber is provided with a feeding port 2, and the outlet end of the kneading chamber is provided with a discharge port 11. The segmented cutter roller includes a pin shaft 8 and multiple hammer holder plates 9, a spun yarn shaft 10, hammer blade spacers 15, rectangular arc toothed hammer blades 19, single-bending hammer blades 20, and double-bending hammer blades 21. The two ends of the spun yarn shaft 10 are rotatably supported on the frame 1 by bearing seats 12. Multiple hammer holder plates 9 are fixedly arranged along the axial direction of the spun yarn shaft 10. The pin shaft 8 passes through each hammer holder plate 9. The hammer blade spacers 15 are sleeved on the pin shaft 8 and located between adjacent hammer holder plates 9. Multiple rectangular arc toothed hammer blades 19, single-bending hammer blades 20, and double-bending hammer blades 21 are all set on the pin shaft 8 and are axially positioned by the hammer blade spacers 15. Along the axial conveying direction of the material, the kneading chamber is sequentially divided into a feeding and guiding zone, a core kneading zone, and a polishing and discharging zone; the large-angle toothed kneading plate 16 is set in the feeding and guiding zone, the fine-toothed kneading plate 17 is set in the core kneading zone, and the arc-shaped toothed kneading plate 18 is set in the polishing and discharging zone; the double-bending hammer 21 is set in the feeding and guiding zone, the single-bending hammer 20 is set in the core kneading zone, and the rectangular arc-shaped toothed hammer 19 is set in the polishing and discharging zone. The inner side of the upper cover plate 3 is uniformly distributed with guide plates 14 along the axial direction. The double bending hammer 21, single bending hammer 20, and rectangular arc tooth hammer 19 are spirally arranged along the circumference of the kneading shaft 10. During the rotation of the segmented cutter roller, the guide plates 14 work together to push the material axially.

[0019] Combination Figure 1-8 As shown, the power transmission assembly includes a driven pulley 4, a belt 5, a driving pulley 6, and a motor 7. The motor 7 is fixedly mounted on the lower part of the frame 1, and the output shaft of the motor 7 is keyed to the driving pulley 6. One end of the segmented cutter roller (i.e., the input end of the kneading shaft 10) is keyed to the driven pulley 4. The driving pulley 6 and the driven pulley 4 are connected by a belt 5. During operation, the motor 7 starts, and its output shaft drives the driving pulley 6 to rotate, transmitting power to the driven pulley 4 via the belt 5, driving the segmented cutter roller to rotate at high speed.

[0020] The shredding chamber is formed by an upper cover plate 3, a lower side plate 13, and a large-angle toothed rubbing plate 16, a fine-toothed rubbing plate 17, and a circular arc toothed rubbing plate 18. The upper cover plate 3 is located at the top of the shredding chamber, and the lower side plate 13 is located at the bottom of the shredding chamber. The large-angle toothed rubbing plate 16, the fine-toothed rubbing plate 17, and the circular arc toothed rubbing plate 18 are arranged sequentially along the material conveying direction at the bottom or side of the inner wall of the shredding chamber. The feeding end of the shredding chamber is provided with a feeding port 2 for feeding the corn stalks to be processed into the shredding chamber; the discharging end of the shredding chamber is provided with a discharge port 11 for discharging the shredded material after shredding from the shredding chamber.

[0021] like Figure 4 As shown, along the axial conveying direction of the material (i.e., from the feed inlet 2 to the discharge inlet 11), the shredding chamber is sequentially divided into a feeding and guiding zone, a core shredding zone, and a polishing and discharging zone. These three zones are connected end-to-end, forming a continuous and progressive axial path for material processing. A large-angle toothed shredding plate 16 is positioned in the feeding and guiding zone, a fine-toothed shredding plate 17 is positioned in the core shredding zone, and a circular arc-toothed shredding plate 18 is positioned in the polishing and discharging zone. The three types of shredding plates have different tooth structures: the large-angle toothed shredding plate 16 has a larger tooth angle, facilitating strong guidance and initial loosening of the straw in the feeding and guiding zone; the fine-toothed shredding plate 17 has fine teeth with a small tooth spacing, which is beneficial for applying intensive shearing and shredding action to the straw in the core shredding zone; and the circular arc-toothed shredding plate 18 has a rounded transition structure at the tooth tip, which is beneficial for gentle surface finishing of the shredded straw in the polishing and discharging zone. The three types of kneading boards work together with the corresponding hammers to achieve a gradual kneading process of straw from weak to strong and then to gentle.

[0022] like Figure 4-8As shown, the segmented cutter roller includes a pin shaft 8, hammer holder plates 9, a kneading shaft 10, hammer blade spacers 15, rectangular arc-toothed hammer blades 19, single-bending hammer blades 20, and double-bending hammer blades 21. The two ends of the kneading shaft 10 are rotatably supported on the frame 1 via bearing seats 12. Multiple hammer holder plates 9 are fixedly arranged along the axial direction of the kneading shaft 10, with each hammer holder plate 9 spaced apart along the axial direction of the kneading shaft 10. Spacers 15 are fitted onto the pin shaft 8 and located between adjacent hammer holder plates 9, used to separate adjacent hammer blades and restrict their axial position. The rectangular arc-toothed hammer blades 19, single-bending hammer blades 20, and double-bending hammer blades 21 are all mounted on the pin shaft 8 and can swing freely around it. The hammer blade spacers 15 achieve axial positioning of each hammer blade, preventing axial movement of the hammer blades on the pin shaft 8.

[0023] like Figure 4-7 As shown, different types of hammer blades are set along the axial direction of the squeezing shaft 10 to correspond to the three zones of the squeezing chamber: In the axial section corresponding to the feeding and guiding zone, multiple double-bending hammer blades 21 are set on the pin shaft 8. The working surface of the double-bending hammer blade 21 is a three-dimensional composite curved surface, that is, the hammer blade is formed by two bending, and its working surface has bending angles in both the horizontal and vertical directions in three-dimensional space. When the segmented cutter roller rotates at high speed, the double-bending hammer 21 hooks the straw through its curved surface structure, grabbing the fed straw and bringing it into the shredding chamber. At the same time, it performs preliminary shredding and tearing of the straw during rotation, achieving preliminary material dispersal. Furthermore, due to the spatial three-dimensional composite curved surface structure of the working surface of the double-bending hammer 21 generating an axial component force during rotation, combined with the action of the guide plate 14, the straw can be pushed axially towards the core shredding area. The double-bending hammer 21 simultaneously achieves the triple functions of hooking, preliminary shredding, and axial pushing of the straw in the feeding and guiding area, preventing the entanglement and accumulation of highly moist straw in the feeding section.

[0024] In the axial section corresponding to the core sizing zone, multiple single-bending hammers 20 are mounted on the pin shaft 8. Each single-bending hammer 20 is formed by a single bending, having a main bending angle. When the straw is pushed into the core sizing zone, the single-bending hammers 20 rotate at high speed with the sizing shaft 10, forming a combined action area with the fixed fine-toothed rubbing plate 17. The single-bending hammers 20 exert a strong shearing effect on the straw, while the relative motion between the hammers and the rubbing plate applies tearing and rubbing forces to the straw, causing the straw fibers to gradually disintegrate and fibrillate under repeated shearing, tearing, and rubbing loading. The fine teeth of the fine-toothed rubbing plate 17 increase the density of action points on the straw per unit area, which is beneficial for improving sizing efficiency and the uniformity of fiber disintegration. In this area, the straw is subjected to sufficient mechanical action, and the fiber bundles are broken up and separated, forming a preliminary fibrillated flocculent material.

[0025] In the axial section corresponding to the polishing discharge area, multiple rectangular arc-toothed hammers 19 are installed on the pin shaft 8. The main body of the rectangular arc-toothed hammer 19 is rectangular plate-shaped, and the working edge of the hammer has arc-shaped teeth with rounded transitions at the tooth tips. When the filamentous straw enters the polishing discharge area, the rectangular arc-toothed hammers 19 rotate at high speed with the shredding shaft 10, forming a combined action area with the arc-toothed rubbing plate 18. The arc-shaped teeth of the rectangular arc-toothed hammers 19 and the arc-shaped tooth tips of the arc-toothed rubbing plate 18 cooperate with each other to apply a relatively gentle rubbing action to the filamentous straw, polishing and finishing the burrs on the surface of the filamentous material, making the fiber surface smoother and the texture softer. At the same time, the centrifugal force generated by the high-speed rotation of the segmented cutter roller throws the polished filamentous material toward the discharge port 11, achieving smooth discharge. The arc structure of the rectangular arc-toothed hammers 19 avoids excessive impact and breakage of the material in the final stage, ensuring the integrity and softness of the finished filament.

[0026] Guide plates 14 are evenly distributed axially along the inner side of the upper cover plate 3. The guide plates 14 are fixedly installed on the inner wall surface of the upper cover plate 3, extending axially from the feeding and guiding area to the polishing and discharging area along the kneading chamber. The inner edge of the guide plates 14 protrudes into the kneading chamber, leaving an appropriate gap with the outer edge of the rotating hammers. Double-bent hammers 21, single-bent hammers 20, and rectangular arc-toothed hammers 19 are arranged in a spiral pattern along the circumference of the kneading shaft 10, meaning that each group of hammers is staggered sequentially at a certain spiral angle along the circumference of the kneading shaft 10. During the rotation of the segmented cutter roller, the hammers in each area generate axial pushing airflow and mechanical thrust, which, combined with the guiding effect of the guide plates 14 fixedly installed on the inner side of the upper cover plate 3, jointly achieve continuous axial pushing of the material. The guide plate 14 guides the material to flow axially along the kneading chamber, preventing the material from rotating circumferentially or mixing axially within the kneading chamber, and ensuring that the material travels unidirectionally along the predetermined path of feeding and guiding zone → core kneading zone → polishing and discharging zone.

[0027] The working surface of the double-bending hammer blade 21 is a three-dimensional composite curved surface structure. This structure is formed by bending in two different directions, so that the working surface of the hammer blade presents a certain bending angle in both the axial and radial directions. This three-dimensional composite curved surface structure allows the double-bending hammer blade 21 to simultaneously complete three actions of hooking and grabbing straw, preliminary kneading and tearing, and axial pushing and guiding within one working cycle of high-speed rotation. Its setting in the feeding and guiding zone plays a key role in the smooth feeding of straw in cold and humid regions and in preventing tangling.

[0028] The rounded-tooth rubbing plate 18 has a rounded transition structure at the tooth tip. Located on the inner wall of the rubbing chamber in the polishing and discharging area, the rounded-edge top of its teeth eliminates sharp corners. When the rounded-tooth rubbing plate 18 works in conjunction with the rectangular rounded-tooth hammer 19, the interaction area between them forms a relatively smooth rubbing gap, preventing the sharp teeth from causing secondary shearing and excessive crushing of the filamentous straw. The rounded transition structure facilitates a gentle polishing of the surface burrs of the filamentous straw, making the finished fiber filaments softer and smoother, thus improving its palatability as forage.

[0029] The guide plates 14 are evenly distributed along the axial direction of the upper cover plate 3. During rotation, the hammers in each area work in conjunction with the guide plates 14 to guide the material axially from the feeding and guiding zone through the core kneading zone to the polishing and discharging zone. The number and spiral angle of the guide plates 14 can be adjusted according to the material characteristics and processing requirements to control the material's travel speed and residence time in the kneading chamber, thereby adjusting the degree of kneading and processing quality.

[0030] Combination Figure 1-8 As shown, a method for progressively shredding corn stalks along an axial section using the aforementioned shredding mechanism includes the following steps: S1 Power Transmission Steps: Start motor 7. The output shaft of motor 7 drives the drive pulley 6 to rotate. The drive pulley 6 transmits power to the driven pulley 4 via belt 5. The driven pulley 4 drives the shredding shaft 10 and the segmented cutter roller fixedly connected to the shredding shaft 10 to rotate at high speed. The rotation direction of the segmented cutter roller should ensure that the material flow direction generated by the rotation of the hammer blades points towards the discharge port 11. By adjusting the speed of motor 7 or replacing the drive pulley 6 and driven pulley 4 with different diameters, the speed of the segmented cutter roller can be adjusted to meet the processing needs of corn stalks with different moisture contents and varieties.

[0031] S2 Feeding and Guiding Step: The corn stalks to be processed (such as corn stalks from cold, high-humidity regions) are fed into the feeding and guiding area of ​​the shredding chamber through the feeding port 2. In the feeding and guiding area, the double-bending hammer blade 21 rotates at high speed with the segmented cutter roller. Its three-dimensional composite curved surface first hooks the stalks, preventing them from accumulating or rebounding at the feeding port 2. As the double-bending hammer blade 21 continues to rotate, the hooked stalks are carried into the working gap between the double-bending hammer blade 21 and the large-angle toothed rubbing plate 16. In this gap, the three-dimensional composite curved surface of the double-bending hammer blade 21 and the large-angle toothed rubbing plate 16 exert a combined effect on the stalks: the hammer blades tear and rub the stalks, while the large-angle teeth of the rubbing plate guide and initially compress the stalks. Through this synergistic effect, the dense structure of the stalks is initially loosened, and the fiber bundles begin to disperse. Meanwhile, the spatial three-dimensional composite curved surface of the double bending hammer 21 generates an axial component force during rotation. Combined with the guiding effect of the guide plate 14 fixedly installed on the inner side of the cover plate 3, it pushes the initially loosened straw along the axial direction to the core shredding area, preventing the high-moisture straw from tangling and accumulating in the feeding and guiding area.

[0032] S3 Core Spunling Step: After initial loosening, the straw enters the core spunling zone and is subjected to the combined action of a single-bending hammer 20 and a fine-toothed spunling plate 17. The high-speed rotation of the single-bending hammer 20 applies a shearing action to the straw, while the relative motion between the side of the hammer and the fine-toothed spunling plate 17 applies tearing and spun action to the straw. The fine teeth of the fine-toothed spunling plate 17 increase the density of the spun action, ensuring that the straw is subjected to uniform mechanical force in all directions. Under the repeated, multi-angle combined loading of the single-bending hammer 20 and the fine-toothed spunling plate 17, the straw fiber bundles are gradually broken up, and the cellulose fibers are fully dissociated and filamentized. The spunling intensity in the core spunling zone is the highest among the three zones, ensuring that the straw completes the key morphological transformation from whole fiber bundles to loose filaments in this area.

[0033] S4 Polishing and Discharging Step: After being fully filamentized in the core filament-rolling zone, the straw enters the polishing and discharging zone, where the rectangular arc-toothed hammer 19 and the arc-toothed rubbing plate 18 work together. Because the working edges of the rectangular arc-toothed hammer 19 are arc-shaped teeth, and the tooth tips of the arc-toothed rubbing plate 18 also have an arc-shaped transition structure, the straw is gently rubbed and polished. When the rectangular arc-toothed hammer 19 rotates, its arc teeth rub and squeeze the surface of the filamentized straw, removing burrs and rough parts from the fiber surface; the arc-toothed rubbing plate 18 provides support and reaction force, making the surface of the filamentous material smoother and the fibers softer. Simultaneously, the centrifugal force generated by the high-speed rotation of the segmented cutter rollers throws the polished filamentous material towards the discharge port 11, from which it exits the filament-rolling chamber, completing the entire filament-rolling process.

[0034] During the shredding process, the material flows axially through the feeding and guiding zone, the core shredding zone, and the polishing and discharging zone, significantly extending the shredding path compared to traditional radial shredders. The effective shredding time of the material within the shredding chamber is effectively controlled through the progressive processing in the three zones, avoiding the insufficient residence time caused by the rapid sweeping of material through a single chamber in traditional models. The differentiated shredding intensity of the three zones precisely matches the dissociation process of straw from whole stalks to filaments: the feeding and guiding zone focuses on hooking, guiding, and initial dissociation with moderate shredding intensity; the core shredding zone focuses on strong shearing and intensive shredding with the highest shredding intensity; and the polishing and discharging zone focuses on gentle finishing and polishing with the lowest shredding intensity. The entire process achieves full dissociation and uniform shredding of high-moisture corn straw without increasing the speed of the segmented cutter rollers or the impact load.

[0035] It is understood that the present invention has been described through some embodiments, and those skilled in the art will recognize that various changes or equivalent substitutions can be made to these features and embodiments without departing from the spirit and scope of the invention. Furthermore, under the teachings of the present invention, these features and embodiments can be modified to adapt to specific situations and materials without departing from the spirit and scope of the invention. Therefore, the present invention is not limited to the specific embodiments disclosed herein, and all embodiments falling within the scope of the claims of this application are within the protection scope of the present invention.

Claims

1. A corn stalk axially partitioned progressive shredding mechanism, comprising a frame (1), a power transmission assembly, a shredding chamber, and segmented cutter rollers, wherein the power transmission assembly and the shredding chamber are both mounted on the frame (1), and the segmented cutter rollers are rotatably disposed within the shredding chamber, characterized in that: The power transmission assembly includes a driven pulley (4), a belt (5), a driving pulley (6) and a motor (7). The motor (7) is fixedly installed on the frame (1). The driving pulley (6) is installed on the output shaft end of the motor (7). The driven pulley (4) is installed on one end of the segmented cutter roller. The driving pulley (6) and the driven pulley (4) are connected by a belt (5). The kneading chamber is formed by an upper cover plate (3), a lower side plate (13), a large-angle tooth kneading plate (16), a fine-tooth kneading plate (17), and a circular arc tooth kneading plate (18). The inlet end of the kneading chamber is provided with a feeding port (2), and the outlet end of the kneading chamber is provided with a discharge port (11). The segmented cutter roller includes a pin (8) and multiple hammer holder plates (9), a spun yarn shaft (10), a hammer blade spacer (15), rectangular arc tooth hammer blades (19), single-bending hammer blades (20) and double-bending hammer blades (21). The two ends of the spun yarn shaft (10) are rotatably supported on the frame (1) through bearing seats (12). Multiple hammer holder plates (9) are fixedly arranged along the axial direction of the spun yarn shaft (10). The pin (8) passes between each hammer holder plate (9). The hammer blade spacer (15) is sleeved on the pin (8) and located between adjacent hammer holder plates (9). Multiple rectangular arc tooth hammer blades (19), single-bending hammer blades (20) and double-bending hammer blades (21) are all set on the pin (8) and are axially positioned by the hammer blade spacer (15). Along the axial conveying direction of the material, the kneading chamber is divided into a feeding and guiding area, a core kneading area, and a polishing and discharging area. The large-angle toothed kneading plate (16) is set in the feeding and guiding area, the fine-toothed kneading plate (17) is set in the core kneading area, and the arc-shaped toothed kneading plate (18) is set in the polishing and discharging area. The double-bending hammer (21) is set in the feeding and guiding area, the single-bending hammer (20) is set in the core kneading area, and the rectangular arc-shaped toothed hammer (19) is set in the polishing and discharging area. The inner side of the upper cover plate (3) is uniformly distributed with guide plates (14) along the axial direction. The double bending hammer (21), single bending hammer (20), and rectangular arc toothed hammer (19) are spirally arranged along the circumference of the kneading shaft (10). During the rotation of the segmented cutter roller, the guide plates (14) work together to realize the axial pushing of the material.

2. The corn stalk axially partitioned progressive shredding mechanism according to claim 1, characterized in that, The working surface of the double-bending hammer (21) is a three-dimensional composite curved surface, which is used to simultaneously realize the functions of straw hooking, preliminary kneading and axial pushing.

3. The corn stalk axially partitioned progressive shredding mechanism according to claim 1, characterized in that, The tooth tip of the circular arc toothed rubbing plate (18) is a circular arc transition structure, which is used to polish the surface burrs of the filamentous straw in conjunction with the rectangular circular arc toothed hammer (19).

4. The corn stalk axially partitioned progressive shredding mechanism according to claim 1, characterized in that, The guide plate (14) is evenly distributed along the axial direction of the upper cover plate (3). The hammers in each area work together with the guide plate (14) during rotation to guide the material to flow directionally from the feeding and guiding area through the core kneading area to the polishing and discharging area along the axial direction.

5. A method for axially partitioned progressive shredding of corn stalks using the shredding mechanism described in any one of claims 1 to 4, characterized in that, Includes the following steps: S1 power transmission steps: Start the motor (7), and drive the skein shaft (10) and segmented cutter roller to rotate at high speed through the transmission action of the drive pulley (6), belt (5) and driven pulley (4); S2 Feeding and guiding steps: Corn stalks are fed into the feeding and guiding area of ​​the shredding chamber through the feeding port (2). The stalks are hooked by double-bending hammers (21). Under the combined action of double-bending hammers (21) and large-angle toothed shredding plates (16), the stalks are initially shredded. At the same time, under the guiding action of the spirally arranged hammers and guide plates (14), the stalks are axially pushed to the core shredding area. S3 Core Fiberizing Step: After the straw enters the core fiberizing zone, it is subjected to repeated loading of shearing, tearing and rubbing under the combined action of the single bending hammer (20) and the fine toothed rubbing plate (17), so that the straw fibers are fully dissociated and filamentized. S4 Polishing and Discharging Steps: After filamentization, the straw enters the polishing and discharging area. Under the combined action of the rectangular arc-toothed hammer (19) and the arc-toothed rubbing plate (18), it is gently rubbed and the surface is polished to form filamentous material. Under the action of centrifugal force generated by the rotation of the segmented cutter roller, it is discharged from the discharge port (11).

6. The shredding method according to claim 5, characterized in that, Throughout the shredding process, by extending the shredding path axially and controlling the material residence time, the high-moisture corn stalks are fully disintegrated and shredded uniformly without increasing the speed of the segmented cutter rollers or the impact load.

7. The shredding method according to claim 5, characterized in that, By differentiating the kneading intensity in three zones—the feeding and guiding zone, the core kneading zone, and the polishing and discharging zone—the process of turning straw from whole stalks into filaments is matched.

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