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基于EDEM的六安瓜片滚筒式烘焙机设计与试验

Design and experiment of drum baking machine for Lu'an Guapian Tea based on EDEM

  • 摘要: 针对目前六安瓜片茶烘焙采用普通滚筒式烘焙机,工艺上不符合六安瓜片传统烘焙工艺,存在碎茶率高,烘焙质量不佳,香气不足等问题,该研究为解决以上问题,根据六安瓜片传统烘焙工艺设计了一种滚筒式茶叶烘焙机。该研究的主要方法在于使用履带式陶瓷电加热带作为加热元件,紧贴外壁安装以降低热阻;滚筒采用变频调速,以适应不同时期生产的茶叶在制品;对茶叶颗粒进行动力学分析,茶叶颗粒在滚筒中的运动由接触、带起及抛落3个阶段组成,并对上述3个阶段的茶叶颗粒分别进行受力分析、建立动力学方程。由相关动力学方程可知:滚筒转速、导叶板螺旋角、导叶板个数、导叶板宽度等因素影响碎茶率及烘焙质量;使用SolidWorks软件构建了虚拟样机,应用EDEM软件建立了茶叶物料的颗粒模型,对茶叶颗粒进行了运动学仿真,通过仿真计算得到了滚筒转速、导叶板螺旋角、导叶板个数、导叶板宽度与茶叶颗粒的平均速度、平均受力的关系,并分析了上述因素对烘焙过程的茶叶破碎率、烘焙质量的影响,确定影响茶叶运动的关键因素。以六安瓜片毛茶为试验材料,为了对上述关键结构参数进行优化,进行了以碎茶率与感官评分为评价目标,以滚筒转速、导叶板螺旋角、导叶板个数为主要因素的3因素3水平二次旋转正交试验,结果表明,影响烘焙效果的主次因素依次为:滚筒转速、导叶板螺旋角、导叶板个数,运用Design Expert 13.0对试验数据进行回归分析,得到以下结论:当滚筒转速为24 r/min,导叶板螺旋角为6°,导叶板个数为5时,茶叶烘焙质量较优。对优化前后的样机验证试验表明:优化前后碎茶率、感官评分由5.86%、86.41分变为4.82%、92.1分,建立的回归方程的预测与试验结果误差小于5%。研究结果可为茶叶烘焙机的设计与优化提供理论借鉴与参考。

     

    Abstract: Lu'an Guapian Tea (also called melon seed) is one type of green tea from Liu'an County in Anhui Province, China. Among them, baking is one of the most important processes in tea processing. Its baking quality can dominate the quality of tea, due to its baking process being different from other famous green tea. It is still lacking in continuous baking equipment, specifically for the Lu'an Guapian Tea. The traditional drum baking machine cannot fully meet the requirements of large-scale production at present, such as the high broken tea rate, poor baking quality, and insufficient aroma. In this study, a drum-type tea baking machine was designed using EDEM software, according to the baking process of the Lu'an Guapian Tea. The crawler-type ceramic belt was used as the electric heating element and then installed close to the outer wall, in order to reduce the thermal resistance. The frequency conversion speed was regulated suitable for the tea products in different periods; Dynamic analysis was carried out to further clarify the motion state of tea in the drum during baking. The tea particles were also moved periodically in the drum. The periodic motion of the tea particles in the drum was composed of three stages: contact, take-up, and drop. The force analysis of the tea particles in the three stages was carried out to establish the dynamic equation. There were influencing factors on the broken tea rate and baking quality, such as the rotation speed of the drum, the helix angle of the guide vane, the number of the guide vane, and the width of the guide vane. The virtual prototype was constructed by SolidWorks software. The particle model of the tea material was established by EDEM software. A numerical simulation was performed on the baking process of the tea particles in the drum. There was a significant relationship between the rotation speed of the drum, the spiral angle of the guide vane plate, the number of the guide vane plate, the width of the guide vane plate, as well as the average speed and average force of the tea particles. The key influencing factors were determined by the movement of the tea particles, even the breaking rate and quality of the tea after baking. Taking the raw tea the Lu'an Guapian Tea as the experimental material, a three-factor and three-level quadratic rotation orthogonal test was carried out to optimize the key structural parameters. The broken tea rate and sensory score were taken as the evaluation objectives, while the drum speed, the spiral angle of the guide vane, and the number of the guide vane were the main factors. The results showed that the primary and secondary influencing factors on the baking were: the drum speed, the spiral angle of the guide vane, and the number of the guide vane. Design Expert 13.0 was used for the regression analysis of the experimental data. An optimal combination of the parameters was: the spiral angle of the guide vane plate was 6°, and the number of the guide vane plates was 5. The better quality of the tea baking was achieved at the drum speed of 24 r/min. The prototype test was carried out to verify before and after optimization. The broken tea rate and sensory score were changed from 5.86% and 86.41 points to 4.82% and 92.1 points, respectively. The relative error between the predicted and the test was less than 5%. The finding can also provide a theoretical reference to optimize the tea-baking machine.

     

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