某烟草加香加料机的设计与仿真研究
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摘要
烟草的加香加料是卷烟生产过程中的一道重要工序,是改善卷烟吸味品质和保持卷烟风格的重要保证,而加香加料机的性能直接决定着烟叶在加香加料过程中的物性变化(如破碎率、温湿度)、烟叶受料受液的均匀性,以及料液的使用效率等。本文对目前国内外广泛使用的德国KAS加香加料机进行了详细的研究调查,分析了其存在的缺陷,并在其基础上创造性地提出了立式气动混合的新方案,设计了完整的设备结构,针对气动混合原理的可行性进行了原理样机的设计、制造、实验及仿真研究,具体工作如下：
(1)总体方案设计
通过对KAS加香加料机及一些传统混合机械、食品加工机械的研究,提出了以气动混合方式代替原KAS机机械混合的方式进行加香加料的总体方案,确定了气动混合加香加料机的功能模块及工作流程；详细设计了加香加料机的各个功能模块子系统,主要包括进出料系统、筒体、布风系统、加香加料系统、热风循环系统等；应用流态化原理和气力输送原理计算确定设备的总体参数。
(2)试验样机的设计及试验研究
针对气动混合加香加料的可行性研究进行了试验样机的工程设计与研制,开展了相应的试验研究工作；根据流场的仿真计算结果与分析结果研究了两种不同孔板开孔方式对筒内气流的影响；根据在试验中发现的问题,分析了试验样机出现不良气泡特性的原因,提出了试验样机布风室的改进措施,并通过理论计算和实验验证了所提改进措施的有效性。
(3)片状颗粒两相流场的数值模拟
由于片状颗粒两相流理论尚不成熟,本文探索性地将颗粒轨道模型应用于片状颗粒两相流场的研究,用形状系数对片状颗粒进行了修正,并采用双耦合计算方式进行了颗粒轨道的确定,仿真结果与试验结果吻合良好。
本文通过原理样机研制、试验研究与数值仿真相结合的研究方法探索了立式气动混合加香加料的技术途径,原理具有可行性,研究成果为进一步实施工程样机奠定了良好的技术基础。
The casing and flavoring is a very important processing procedure of the cigarette production because it is the guarantee of the cigarette smoking quality and style, and the performance of the casing and flavoring machine is the key to the physical change (such as the breakage percentage, temperature and humidity) and the uniformity of the casing and flavoring as well as the use efficiency of flavor liquid during the process. In this article, a detailed investigation of the Germany KAS widely used presently was made, and its defects were analyzed. Based on the above work, a new type scheme of vertical air mixing was proposed, and the complete device structure was designed. Besides, a test prototype was designed and made, and the feasibility of the air mixing manner was simulated and verified.
The specific works as follows:
(1) Design of overall scheme
A new type of vertical air mixing program was proposed based on the researches on the traditional mixed machinery and food processing machinery, the detailed function parts was designed, mainly including the in-out tobacco system, cylinder, air distribution system, casing and flavoring system and hot air circulation system. Additionally, the general parameters of the machine were calculated with fluidized bed principle and pneumatic conveying theory.
(2) Design and researches on test prototype
A test prototype was designed and manufactured, and the corresponding experiments were carried out. The feasibility of the air mixing manner was verified. A contrast of two different orifices was made based on the simulation and analysis of the flow field. Besides, an analysis of poor bubble characteristics was made based on the problems found in the experiment, and an improvement of the air distribution room was made and the effect of the improvement was proved both in the theoretical calculations and experiments.
(3) Simulation of the flaky particles-air two-phase flow field
The DPM model was used for the researches on flaky particles-air two-phase flow field as there was no mature theory for it. The shape factor was used to correct the calculation, and the orbit of the flaky particles in the air flow field was determined with double coupling, the simulation result was in good agreement with experiment result.
In this paper, theory and experimental studies are carried out on the feasibility of the new type of vertical air mixing manner, the results showed that it has feasibility. The studies established the foundation for the development of the engineering prototype.
(1)总体方案设计
通过对KAS加香加料机及一些传统混合机械、食品加工机械的研究,提出了以气动混合方式代替原KAS机机械混合的方式进行加香加料的总体方案,确定了气动混合加香加料机的功能模块及工作流程；详细设计了加香加料机的各个功能模块子系统,主要包括进出料系统、筒体、布风系统、加香加料系统、热风循环系统等；应用流态化原理和气力输送原理计算确定设备的总体参数。
(2)试验样机的设计及试验研究
针对气动混合加香加料的可行性研究进行了试验样机的工程设计与研制,开展了相应的试验研究工作；根据流场的仿真计算结果与分析结果研究了两种不同孔板开孔方式对筒内气流的影响；根据在试验中发现的问题,分析了试验样机出现不良气泡特性的原因,提出了试验样机布风室的改进措施,并通过理论计算和实验验证了所提改进措施的有效性。
(3)片状颗粒两相流场的数值模拟
由于片状颗粒两相流理论尚不成熟,本文探索性地将颗粒轨道模型应用于片状颗粒两相流场的研究,用形状系数对片状颗粒进行了修正,并采用双耦合计算方式进行了颗粒轨道的确定,仿真结果与试验结果吻合良好。
本文通过原理样机研制、试验研究与数值仿真相结合的研究方法探索了立式气动混合加香加料的技术途径,原理具有可行性,研究成果为进一步实施工程样机奠定了良好的技术基础。
The casing and flavoring is a very important processing procedure of the cigarette production because it is the guarantee of the cigarette smoking quality and style, and the performance of the casing and flavoring machine is the key to the physical change (such as the breakage percentage, temperature and humidity) and the uniformity of the casing and flavoring as well as the use efficiency of flavor liquid during the process. In this article, a detailed investigation of the Germany KAS widely used presently was made, and its defects were analyzed. Based on the above work, a new type scheme of vertical air mixing was proposed, and the complete device structure was designed. Besides, a test prototype was designed and made, and the feasibility of the air mixing manner was simulated and verified.
The specific works as follows:
(1) Design of overall scheme
A new type of vertical air mixing program was proposed based on the researches on the traditional mixed machinery and food processing machinery, the detailed function parts was designed, mainly including the in-out tobacco system, cylinder, air distribution system, casing and flavoring system and hot air circulation system. Additionally, the general parameters of the machine were calculated with fluidized bed principle and pneumatic conveying theory.
(2) Design and researches on test prototype
A test prototype was designed and manufactured, and the corresponding experiments were carried out. The feasibility of the air mixing manner was verified. A contrast of two different orifices was made based on the simulation and analysis of the flow field. Besides, an analysis of poor bubble characteristics was made based on the problems found in the experiment, and an improvement of the air distribution room was made and the effect of the improvement was proved both in the theoretical calculations and experiments.
(3) Simulation of the flaky particles-air two-phase flow field
The DPM model was used for the researches on flaky particles-air two-phase flow field as there was no mature theory for it. The shape factor was used to correct the calculation, and the orbit of the flaky particles in the air flow field was determined with double coupling, the simulation result was in good agreement with experiment result.
In this paper, theory and experimental studies are carried out on the feasibility of the new type of vertical air mixing manner, the results showed that it has feasibility. The studies established the foundation for the development of the engineering prototype.
引文
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[2]张楚安,尤长虹等.多喷头加香加料装置：中国,200620098661[P].2006-8-15
[3]邓勇,李永泽等.滚摆式烟草加料、加香混合设备：中国,200320114479[P].2003-11-4
[4]J. H. KESTER. TOBACCO CASING AND FLAVORING MACHINE[P]美国：541283，1895.06.18
[5]P. H. HAWKINS. APPARATUS FOR CASING AND FLAVORING TOBACCO[P].美国：687308,1901.11.26
[6]王琳.国产烟机发展回顾与展望.伺服控制,2008(1)：106-107
[7]张楚安,尤长虹,吴贵兵,刘辉.多喷头加香加料装置[P].中国：200620098661,2006.08.25
[8]邓勇,李永泽.滚摆式烟草加料、加香混合设备[P].中国：CN200320114479.9,2003.11.04
[9]雷东锋.双璧两点喷射加料加香装置[P].中国：200620078360,2006.02.10
[10]贺孟春,刘东,刘晓宇,丁永青.卷烟材料暂存高架库温湿度场的优化控制研究.烟草科技,2008(7)：16～18
[11]刘晓宇,刘东.恒温恒湿立体仓库孔板送风的影响因素及参数优化.能源技术,2008(6)：381-384
[12]李莹.卷烟厂绿色工房项目中的建筑环境模拟.暖通空调,2009(5)：27-28
[13]陈惠斌.武汉卷烟厂联合工房节能方案.建设科技,2010(8)：60～61
[14]龚超.某卷烟厂空调风系统能耗测试与分析.建筑热能通风空调,2009(3)：76-79
[15]Fukuchi J, Ohtake Y, Hanaoka C. A Numerical Fluid Simulation for A Pneumatic Conveying Dryer of Cut Tobacco. CORESTA,2000
[16]周晖.卷烟厂的气力输送技术应用参数设计优化.[硕士论文].南昌大学,2005
[17]Dimitri Gidaspow. Multiphase Flow and Fluidization-continuum and Kinetic Theory Descriptions. Academic Press, USA (1994)
[18]管锋,周传喜,陈君若,刘亦坚.高温管式膨胀系统的结构优化与模拟.烟草科技,2000(1)：25-26
[19]Csanady. G. T. Turbulent Diffusion of Heavy Particles in the Atmosphere. Journal of Atmosphere Science, Vol.20, Issue 3,201～208
[20]C. Simonin and P. L. Viollet. Predictions of An Oxygen Droplet Pulverization in A Compressible Subsonic Co-flowing Hydrogen Flow. Numerical Methods for Multiphase Flows, FED91:65～82,1990
[21]耿凡,袁竹林,王宏生.流化床中烟丝颗粒的流动特性.东南大学学报.2009(5)：1012～1014
[22]唐向阳,张勇,陈猛,关宏.烟草异物剔除系统中高速皮带机风压系统的流场有限元分析.机械科学与技术.2002(22)：43-45
[23]朱国庆,程远平.大空间卷烟制丝车间烟气控制性能化设计.西安建筑科技大学学报.2007(5)：621-623
[24]杨伦,谢一华.气力输送工程.北京：机械工业出版社,2005.92
[25]孙研.风机产品样本.北京：机械工业出版社,2003.1888-1890
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