Modification of medium density fiberboard chip production line
Guangxi Sanwei Forest Products Industry Co., Ltd. (formerly Guangxi Luzhou Lumber Factory) started production of 100,000 m3 MDF production line in 1997, which was introduced from Shunzhi Company of Sweden. The entire line of processes and equipment are designed or selected by Ruifang. The main equipment is provided by Ruifang. If some of the equipment cannot be transported or non-main equipment, the design parameters or drawings provided by Ruifang will be manufactured in China. After one year of operation of the production line, we found that the main factor that constrains the efficiency of the production line and affects the capacity of the production line is the chip preparation system. In response to this situation, we have made a series of improvements to the wood chip preparation system and achieved remarkable results.
1 the original state of the wood chip preparation system
1.1 The process flow of the log preparation system is omitted after some cycles not related to this paper, as shown in Figure 1.
1 . 2 major problems in the wood chip preparation system
1.2.1 No. 1 has a feed width of 500rnm and a length of 35000~, while its drive roller is only 5. The 5kW electric roller has been found to have insufficient power and is easily overloaded and burned. It is difficult to remove the electric roller from the belt conveyor after burning, and the maintenance of the electric roller itself is relatively complicated and difficult, and the fault cannot be quickly processed.
1.2.2 The two-way belt conveyor of serial number 5 is installed on the top of two wood chip bins with a height of 12m. Due to the defects of design and manufacture, when the wood chips are transported, the wood chips leak a lot from their inlet and outlet interfaces and the side of the belt. Or the sawdust floated down from the top of the 12m high warehouse as follows, the entire production site was a mess, no one dared to approach. More deadly, there will be a piece of wood that is brought into the leak between the bottom of the wood feeding belt and the tank body, causing the belt to run off, not working properly and scratching the edge of the belt, causing damage and failure of the belt. On average, a belt must be replaced every month. The belt costs about 10,000 yuan, and the belt conveyor is at high altitude. Maintenance is even more difficult.
1 . 2.3 The belt conveyor of serial number 8 also has the problem of the two-way belt conveyor of serial number 5. It is also necessary to replace one belt of about 10,000 yuan per month on average. The wood chips leaked from the two belt conveyors were cleaned by two workers every day.
1.2.4 The wood chip chute of No. 11 is welded on the screening machine, and the wood chips are conveyed by swinging together with the screening machine, often falling off at the welding place, which affects the continuity of production. Although multiple reinforcing ribs are added, the effect is not satisfactory. 1.2.5 The wood chip conveying pump and conveying pipe of No. 15 are easy to be blocked, and the cleaning and clogging needs to empty the wood piece washing and mixing box and disassemble the pipe, which is time-consuming and laborious, and the maintenance labor intensity is large.
The above problems lead to the continuous production of the entire production line due to the intermittent supply of wood chips. The automated production line cannot be continuously produced, which seriously restricts the production capacity, limits the production, increases the consumption and cost of production, and greatly affects the stability of product quality. , reducing the pass rate of the product.
2 reasons analysis and improvement measures
The improved wood chip preparation system is shown in the figure below.
2.1 For the shortcomings of the power roller of the main drive of the serial number belt conveyor and the difficulty of repairing the electric roller, the driving power is increased to 7. SKW by calculation, and the electric roller is changed into a general roller. The cylinder is driven by the cycloid reducer through the roller chain drive, which greatly reduces the failure rate and improves the convenience of maintenance.
2.2 Change the two-way belt conveyor of serial number 5 to the pneumatic trouser-shaped distributor, as shown in Figure 2, 19, by the self-weight of the wood chip, the pipe is closed, eliminating the leakage of the wood chip, saving power energy and saving the average monthly A belt of about 10,000 yuan. Thanks to the proof of use, this distributor is almost maintenance-free and works very well.
2.3 Change the belt conveyor of No. 8 to a screw conveyor (No. 20), and also achieve the effect of saving an average belt of about 10,000 yuan per month, and also eliminate the leakage of wood chips, reducing the trouble, and basically eliminating the cleaning. Labor, saving labor.
2.4 Add the upper wood chip system with serial number 23 as shown in Figure 2, for the placement of the purchased wood chips, to prevent the serial number 1, 2, 3, 4 and other equipment from failing to supply the wood chips and the whole line to break, so as to improve the production of the production line. effectiveness.
2.5 In the same way, the addition of 24,25 wood chips by weight drop pipe bypass is added to prevent the failure of the chip bin discharge system and the wood chip screening machine, and the continuity of the whole line production is often guaranteed at critical moments.
2.6 Cancellation of the wood chip chute of serial number 11 is replaced by a screw conveyor placed on the ground and completely removed from the screening machine, which greatly reduces the failure of the whole line to be discontinued due to some simple reasons.
2 . 7 By careful observation, measurement, calculation and analysis, the blockage of the chip pump and the conveying pipe is mainly due to the poor effect of the rolling vortex formed by the wood chip mixture in the wood piece washing and mixing box of No. 13 and the wood chips cannot be fully contained in the box. Rolling and mixing, it is easy to deposit in front of the pump population, and the power of the wood chip pump is insufficient, and the conveying capacity is not enough. Therefore, we have added 1 power to 7. Skw, a circulating pump 22 with a flow rate of 70m3 / h and a head of 15.6m, taking water from the circulation tank to the inlet of the washing machine, increasing the amount of water in the mixing tank of the washing machine and enhancing the vortex in the mixing tank, which can prevent The wood chips are deposited in front of the pump, and can also be diluted to dilute the concentration of the wood chip mixture; after studying the characteristic curve of the No. 15 wood chip pump, it is found that the capacity of the wood chip pump is still relatively rich, so the speed of the pump is driven by the belt drive system. The increase, thereby increasing the pump's conveying capacity, while increasing the power of the drag motor of the chip pump from SSkW to 75 kW, solves the thorny problem of clogging, and the effect is satisfactory.
3 summary
Through the transformation of the wood chip preparation system, not only the labor intensity of maintenance and cleaning of workers is reduced, the monthly spare parts cost is more than 20,000 yuan, the production environment is improved, and the main reason is that the frequency of the whole line is greatly reduced, and the post-process is solved. The problem of rice pots ensures the continuity of production across the board, which effectively saves energy and other consumption, reduces production costs, greatly increases production, and achieves stable product quality. After several years of use, the effect of technological transformation is very significant, and the output has increased from an average of 8,000 per month to about 9 SOOni3 per month.
Guangxi Sanwei Forest Products Industry Co., Ltd. (formerly Guangxi Luzhou Lumber Factory) started production of 100,000 m3 MDF production line in 1997, which was introduced from Shunzhi Company of Sweden. The entire line of processes and equipment are designed or selected by Ruifang. The main equipment is provided by Ruifang. If some of the equipment cannot be transported or non-main equipment, the design parameters or drawings provided by Ruifang will be manufactured in China. After one year of operation of the production line, we found that the main factor that constrains the efficiency of the production line and affects the capacity of the production line is the chip preparation system. In response to this situation, we have made a series of improvements to the wood chip preparation system and achieved remarkable results.
1 the original state of the wood chip preparation system
1.1 The process flow of the log preparation system is omitted after some cycles not related to this paper, as shown in Figure 1.
1 . 2 major problems in the wood chip preparation system
1.2.1 No. 1 has a feed width of 500rnm and a length of 35000~, while its drive roller is only 5. The 5kW electric roller has been found to have insufficient power and is easily overloaded and burned. It is difficult to remove the electric roller from the belt conveyor after burning, and the maintenance of the electric roller itself is relatively complicated and difficult, and the fault cannot be quickly processed.
1.2.2 The two-way belt conveyor of serial number 5 is installed on the top of two wood chip bins with a height of 12m. Due to the defects of design and manufacture, when the wood chips are transported, the wood chips leak a lot from their inlet and outlet interfaces and the side of the belt. Or the sawdust floated down from the top of the 12m high warehouse as follows, the entire production site was a mess, no one dared to approach. More deadly, there will be a piece of wood that is brought into the leak between the bottom of the wood feeding belt and the tank body, causing the belt to run off, not working properly and scratching the edge of the belt, causing damage and failure of the belt. On average, a belt must be replaced every month. The belt costs about 10,000 yuan, and the belt conveyor is at high altitude. Maintenance is even more difficult.
1 . 2.3 The belt conveyor of serial number 8 also has the problem of the two-way belt conveyor of serial number 5. It is also necessary to replace one belt of about 10,000 yuan per month on average. The wood chips leaked from the two belt conveyors were cleaned by two workers every day.
1.2.4 The wood chip chute of No. 11 is welded on the screening machine, and the wood chips are conveyed by swinging together with the screening machine, often falling off at the welding place, which affects the continuity of production. Although multiple reinforcing ribs are added, the effect is not satisfactory. 1.2.5 The wood chip conveying pump and conveying pipe of No. 15 are easy to be blocked, and the cleaning and clogging needs to empty the wood piece washing and mixing box and disassemble the pipe, which is time-consuming and laborious, and the maintenance labor intensity is large.
The above problems lead to the continuous production of the entire production line due to the intermittent supply of wood chips. The automated production line cannot be continuously produced, which seriously restricts the production capacity, limits the production, increases the consumption and cost of production, and greatly affects the stability of product quality. , reducing the pass rate of the product.
2 reasons analysis and improvement measures
The improved wood chip preparation system is shown in the figure below.
2.1 For the shortcomings of the power roller of the main drive of the serial number belt conveyor and the difficulty of repairing the electric roller, the driving power is increased to 7. SKW by calculation, and the electric roller is changed into a general roller. The cylinder is driven by the cycloid reducer through the roller chain drive, which greatly reduces the failure rate and improves the convenience of maintenance.
2.2 Change the two-way belt conveyor of serial number 5 to the pneumatic trouser-shaped distributor, as shown in Figure 2, 19, by the self-weight of the wood chip, the pipe is closed, eliminating the leakage of the wood chip, saving power energy and saving the average monthly A belt of about 10,000 yuan. Thanks to the proof of use, this distributor is almost maintenance-free and works very well.
2.3 Change the belt conveyor of No. 8 to a screw conveyor (No. 20), and also achieve the effect of saving an average belt of about 10,000 yuan per month, and also eliminate the leakage of wood chips, reducing the trouble, and basically eliminating the cleaning. Labor, saving labor.
2.4 Add the upper wood chip system with serial number 23 as shown in Figure 2, for the placement of the purchased wood chips, to prevent the serial number 1, 2, 3, 4 and other equipment from failing to supply the wood chips and the whole line to break, so as to improve the production of the production line. effectiveness.
2.5 In the same way, the addition of 24,25 wood chips by weight drop pipe bypass is added to prevent the failure of the chip bin discharge system and the wood chip screening machine, and the continuity of the whole line production is often guaranteed at critical moments.
2.6 Cancellation of the wood chip chute of serial number 11 is replaced by a screw conveyor placed on the ground and completely removed from the screening machine, which greatly reduces the failure of the whole line to be discontinued due to some simple reasons.
2 . 7 By careful observation, measurement, calculation and analysis, the blockage of the chip pump and the conveying pipe is mainly due to the poor effect of the rolling vortex formed by the wood chip mixture in the wood piece washing and mixing box of No. 13 and the wood chips cannot be fully contained in the box. Rolling and mixing, it is easy to deposit in front of the pump population, and the power of the wood chip pump is insufficient, and the conveying capacity is not enough. Therefore, we have added 1 power to 7. Skw, a circulating pump 22 with a flow rate of 70m3 / h and a head of 15.6m, taking water from the circulation tank to the inlet of the washing machine, increasing the amount of water in the mixing tank of the washing machine and enhancing the vortex in the mixing tank, which can prevent The wood chips are deposited in front of the pump, and can also be diluted to dilute the concentration of the wood chip mixture; after studying the characteristic curve of the No. 15 wood chip pump, it is found that the capacity of the wood chip pump is still relatively rich, so the speed of the pump is driven by the belt drive system. The increase, thereby increasing the pump's conveying capacity, while increasing the power of the drag motor of the chip pump from SSkW to 75 kW, solves the thorny problem of clogging, and the effect is satisfactory.
3 summary
Through the transformation of the wood chip preparation system, not only the labor intensity of maintenance and cleaning of workers is reduced, the monthly spare parts cost is more than 20,000 yuan, the production environment is improved, and the main reason is that the frequency of the whole line is greatly reduced, and the post-process is solved. The problem of rice pots ensures the continuity of production across the board, which effectively saves energy and other consumption, reduces production costs, greatly increases production, and achieves stable product quality. After several years of use, the effect of technological transformation is very significant, and the output has increased from an average of 8,000 per month to about 9 SOOni3 per month.
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