Straw Biomass Granulator Forming Device
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Solution Overview
Problem
Existing straw biomass granulators face challenges in miniaturization due to high energy consumption and inefficiencies in processing loose straw, leading to fragile granules, reduced production efficiency, and increased equipment size.
Innovation Solution
A trailed straw biomass granulator with a forming device featuring involute sliding teeth and reset springs that increase material feeding capacity without enlarging the gear, combined with a preload device and vacuum pump to enhance material compaction and moisture management, allowing for more efficient granule production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the gear size is increased to increase feeding volume and discharge speed, then the granulating speed improves, but the overall equipment size becomes larger and energy consumption increases
Solution Approach 1:
The gear is segmented into multiple functional zones: material feeding area, compacting area with gradually deepening tooth grooves, and forming hole area. This segmentation allows each zone to perform its specific function efficiently, maximizing the utilization of gear volume without increasing overall size.
Solution Approach 2:
The tooth grooves are designed with gradually increasing depth from the material inlet toward the forming hole, creating preliminary compaction zones. This preliminary action compresses the loose straw before it enters the forming hole, increasing material density and feeding efficiency without requiring larger gear dimensions.
2Manufacturing precision
If the forming hole path is extended to fully compact loose straw, then granule density improves, but production efficiency decreases due to reduced storage capacity and slower material feeding
Solution Approach 1:
Different regions of the gear have different tooth groove depths tailored to local requirements. The compacting area has progressively deeper grooves for dense material compression, while the forming hole region maintains optimal depth for efficient granule formation. This localized optimization achieves high density without sacrificing production speed.
Solution Approach 2:
The gradually deepening tooth grooves perform preliminary compaction of loose straw before it reaches the forming hole. This preliminary compression reduces the required path length in the forming hole itself, allowing full compaction to be achieved in a shorter distance, thus maintaining both density and production efficiency.
3Manufacturing precision
If the tooth profile meshing pressure is increased to compact material effectively, then material compaction improves, but power consumption increases and key parts experience severe wear
Solution Approach 1:
The tooth profile is designed with varying pressure distribution: higher contact pressure in the compacting area where deep grooves progressively compress material, and optimized pressure in the forming hole area. This localized pressure optimization achieves effective compaction while minimizing overall power consumption and wear.
Solution Approach 2:
Material compaction is performed progressively through the gradually deepening tooth grooves before material enters the forming hole. This preliminary compaction reduces the compaction burden in the forming hole region, distributing the compression work over a longer sequence of incremental steps, thereby reducing peak power requirements and wear on critical components.
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
The solution improves production efficiency, reduces energy requirements, and enables a more compact design by effectively compacting and processing loose straw into denser granules, addressing issues of fragile products and high energy consumption.
Implementation Method 1
the forming gear comprises a base body, a plurality of involute sliding teeth and a plurality of reset springs; the sliding teeth are evenly distributed on the peripheral side of the base body in the circumferential direction, and the sliding teeth are slidably arranged on the base body
Implementation Method 2
the reset springs are located inside the sliding grooves, one end of the reset spring is fixedly connected inside the sliding grooves, and the other end is fixedly connected to the slide block
Implementation Method 3
combined with a preload device and vacuum pump to enhance material compaction and moisture management
Data Source
AI summary
A trailed straw biomass granulator includes a first drive device and a forming device. The forming device includes a driving gear and a forming gear. The driving gear is evenly distributed with involute drive teeth along a circumference. A storage groove is formed between every two adjacent drive teeth. The driving gear includes an output hole in an axial direction, and an auger is arranged inside the output hole. A forming hole is defined between two adjacent drive teeth, and the forming hole penetrates into the output hole and the storage groove. The forming gear includes a base body, multiple involute sliding teeth and multiple reset springs, and the sliding teeth are evenly distributed on the peripheral side of the base body in a circumferential direction. The base body includes multiple sliding grooves in one-to-one correspondence with the sliding teeth, which are integrally formed with a slide block.