竹材自动定段设备的设计与样机试验

Design and prototype test of bamboo automatic segmentation equipment

竹材凭借其生长周期短、力学性能好、绿色环保等优异特点,具有较高的经济和社会价值,逐渐得到规模化开发利用,但目前竹材加工机械普遍存在自动化程度低、劳动强度大、安全系数低等问题,难以满足现代高质量竹材加工品生产的需求,极大限制了竹材加工行业的发展,竹材加工机械急需向自动化、连续化、智能化方向进行发展。设计了一款基于可编程控制器(PLC)控制的竹材自动定段设备,可实现竹材自动进料、去竹篼、可调定长定段、竹节自动识别、竹节有效精准避让、规格化竹段自动出料、去竹梢等功能,实现了竹材定段工序的自动加工,大幅提高了竹材加工的机械化、自动化水平,同时减少了安全隐患。通过对竹材自动定段设备的现场试验,能够实现竹材自动定段的功能,基本达到了设计要求,竹节避让率可达100%,平均加工效率约10.16 m/min,竹梢有效保留率100%,定段效率比人工至少提高27%,降低劳动力成本50%以上,仅需一人操作设备,适合实际生产的需要,为后续实现竹材初加工全程机械化提供了条件。

Bamboo has high economic and social value due to its short growth cycle, good mechanical properties and environmental protection performs, which has gradually been developed and utilized on a large-scale production. However, the current bamboo processing machinery generally has problems such as low automation, high labor intensity and low safety factor. It is difficult to meet the needs of modern high-quality bamboo products, which greatly restricts the development of the bamboo processing industry. The bamboo processing machinery urgently needs to be developed in the direction of automation, continuity and intelligence. Bamboo laminated timber products are one of the important products used in the industrialization of bamboo. Its initial processing generally includes three major processing steps: fixed-stage processing, bamboo-breaking processing, and rough milling. Bamboo segmentation processing refers to sawing and cutting bamboo into bamboo tubes of equal specifications along the circumferential direction. At present, the fixed segment processing of bamboo is mostly carried out by manual operations of the cutting saw, which manually completes a series of actions such as feeding, moving, positioning, pressing, and operating the saw to cut the raw bamboo. According to the requirements of the bamboo breaking machine, there should be no bamboo joints in the bamboo section within 50 mm from the small end, and the bamboo joints avoidance shall be judged and executed manually. This study designed an automatic bamboo segmentation equipment based on the programmable logic controller control, which could realize bamboo material automatic feeding, bamboo basket removal, adjustable length and segmentation, automatic recognition of bamboo joints, effective and precise avoidance of bamboo joints, and automatic discharge of standardized bamboo sections. The functions of feeding and removing bamboo shoots had realized for the automatic fixed-stage processing of bamboo, which had greatly improved the mechanization and automation level of bamboo processing and reduced potential safety hazards. Through the field tests of the bamboo automatic segmentation equipment, the function of bamboo automatic segmentation could be realized, which basically met the design requirements. The bamboo joint avoidance rate could reach 100%, the average processing efficiency was about 10.16 m/min, and the effective retention rate of bamboo shoots was 100%. The efficiency of the fixed section was at least 27% higher than that of manual labors, and labor costs were reduced by more than 50%. Only one person was required to operate, which was suitable for practical uses. This developed equipment provides conditions for the subsequent realization of the mechanization of the whole process of bamboo material processing.