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16MODELING OF OPERATING MODES OF THE MODULE OF CLEANING THE VACUUM-SORTING-DRYING MACHINE DURING THE PRODUCTION OF FROZEN SEMI-PRODUCTS
FROM THE POTATO
Khrameshin R.
1st year PhD student at the graduate school Izhevsk State Agricultural Academy
Enders M.
veterinary doctor, magister Izhevsk State Agricultural Academy
Khrameshin A.
Scientific Advisor, Candidate of Technical Sciences, Associate Professor of the Department of Life Safety Izhevsk State Agricultural Academy
Abstract
The article analyzes the issues of modeling the modes of operation of the cleaning module of a vacuum-grading and drying machine, taking into account the factors of processed raw materials in the production of potato products. The main reasons for the decline in the quality of sorting potato products are considered.
Keywords: potato, starch, sorting, vacuum, technology, modeling, sorting, drying, machine.
Introduction
Under the conditions of the Udmurt Republic, potatoes are one of the main food and feed crops. The constant growth of its consumption requires an increase in production, development of new crop varieties with high feed and nutritional value [2], improvement of cultivation technologies and subsequent post-harvest processing, [1].
In the quality of the technical and economic coefficients are often used indicators of quantitative dependence between the costs of resources and output. For their calculation, production functions that express the relationship between the production results and the corresponding costs are successfully applied, [3]. They allow you to calculate the cost coefficients, efficiency and interchangeability factors, develop parameters and predict the level of results of the processing industry.
The purpose of the work - is to consider the main causes of contamination of the working surface of the sorting drum; to simulate the modes of operation of the cleaning module; to identify the relationship between the modes of operation of the machine and the starch content in the processed potatoes, as well as other factors affecting the contamination of the working surface of the sorting drum; suggest solutions to this problem.
To obtain high-quality small-sized semi-finished products, it is necessary in the production process to carry out the operation of sorting the product by size in order to continue processing in the optimal mode and obtain a quality product. In this case, it will be necessary to change the process line [3], since the heap sorting occurs at atmospheric pressure (constant contact of oxygen from the air with the cut surface of vegetables); for this, cutting of vegetable raw materials and sorting of this pile should be carried out in a discharged environment.
The following tasks will be solved:
• exclusion of the contact of cut potatoes with air; after cutting, a pile of potatoes enters the sorting machine;
• compactness and small-sized installation, as well as mechanization and automation of the process, which leads to a reduction in total costs;
• potatoes will not be subjected to heat treatment, also during freeze-drying the temperature of the potatoes decreases;
• production line will be reduced, the need for production space.
The workflow of sorting of any type is based on sifting through the separation holes of particles whose size is smaller than the size of the holes. Therefore, the study begins with the study of the dimensional characteristics of the particles to be divided into fractions in the process of technological processing.
Obtaining a product that is uniform in size, shape, color and degree of maturity allows the use of economical modes of heat treatment, prevents cooking and ensures rational management of the process.
In addition to standard cubes, small particles (trimmings) are formed, the number of which varies depending on the size and shape of the material. The presence of scraps leads to a decrease in the quality of the finished product, as small particles begin to boil soft beforehand, or burn during frying. In this regard, the process of production of quick-frozen potatoes requires the process of cutting off the cut from the standard cut particles. The value by which sorting is performed should be controlled in the separation process with a simple, reliable and high-performance device; proportionally and uniquely reflect the size of the product; have a large range of variation and be universal, that is suitable for particles of different shapes and sizes.
In the process of sorting, a heap of product is continuously circulating, rising along concentric circular paths and rolling down parallel layers in a cascade downwards. This sorting mode is called cascade (figure 1a).
With a slight increase in the frequency of rotation of the drum, the cubes of the product along circular trajectories rise higher and higher, but the operating mode may still remain cascade. When, finally, the cubes rise to a known, even greater height, determined by the frequency of rotation of the drum, they will descend from circular trajectories and, like bodies thrown at an angle to the horizon, along a parabolic trajectory will fall like a waterfall back into circular trajectories. This sorting mode is called waterfall (Figure 1b), [6].
a) b)
Figure 1 - Cascade and waterfall types
The position of the column on the circular path is determined by the separation angle a, with the formed radius of the sorting drum passing through the center of the column, with the vertical diameter of the drum.
This condition is satisfied if the installation parameters are correctly selected. The number of separation sorting holes depends on the diameter of the drum. The width of the separating gaps is dictated by the particle
12
a) 5
size, therefore, the size of the lumen should be smaller than the specified sizes, and at the same time there was the possibility of sorting the columns of both 7 * 7 and 13 * 13 mm, Figure 2 shows the possible variants modeled using the Compass CAD system, it is taken into account that a wire of a certain diameter is used in the form of a thread, the size of which affects the size of the sorting slot, [4].
12,5
J=±±
5,5
13
ej
13
5,5
14
13,5 -
6,5
14,5
14 , 6A3
Figure 2 - Possible options for the width of the separation gap a - 7.0 mm pitch, b - 7.5 mm pitch, c - 8.0 mm pitch.
From the analysis it can be seen that with a drum diameter of 0.350 m the most acceptable option: a pitch is 7.0 mm, a thread diameter is 2.0 mm, a lumen width is 5.0 mm, for 7 * 7 posts, and for 13 * 13 mm, while
taking into account the error in the manufacture, sagging threads and the relative displacement of the threads relative to each other.
Figure 3 - Visualization of the sorting process, according to calculated points
Screw threads will provide lifting and moving particles inside the drum. The curvature (elevation angle of the helix y) can be adjusted by special grooves made in one of the discs, thereby reducing or increasing the screening time for a pile of potatoes, [5].
Thus, the main causes of contamination of the working surface of the yarn sorting drum are:
• the cut, obtained after cutting the potato, in the process of sorting clogs the free space between the threads;
• starch, which sticks to the yarn during the sorting of potato products, due to its adhesive ability;
• freezing of potato cuttings on working threads during vacuum processing.
The main varieties received for processing in Udmurtia are the middle early - Nevsky (standard), Svi-tanok Kiev, Lukyanovsky, Elizabeth; middle-end -Lugovskoy (standard), Lorch, Pace, Olympus, Niku-linsky, Chaika.
They have three forms of tubers: round, round-oval and oval. Measurements related to the analysis of the composition and properties of the product (mixture) are based on the use of dependencies between the composition of the analyzed product (or concentrations of its components) and the values characterizing its physical or physicochemical parameters:
y=fi (CiA,..., Cn), (1)
Where: y - is the measured parameter of the analyzed product (mixture);
C1, C2, ..., Cn - is the concentration of components (or the amount of the product);
n - is the total number of components contained in the analyzed product.
One of the effective ways to implement a multiparameter computational method for analyzing the composition of complex mixtures is the use of a special apparatus of the theory of probability, [7]. In this case, finding a regression equation characterizing the quality of the product being analyzed can be reduced to finding dependencies between a single generalizing qualitative
indicator and individual qualitative integral or selective parameters depending on the content of the components of the analyzed product (mixture).
Thus, finding a generalized quality indicator of the analyzed product (mixture) can be reduced to measuring a small number of integral parameters and solving the found regression equation characterizing the relationship between these parameters and the quality of the analyzed product (mixture).
According to the technical conditions, the trimmings should not be more than 5 ... 8% of the total, so the sorting operation is one of the most important. The main indicators characterizing the sorting process are the sorting accuracy r, productivity and damageability. Experience and model show [8] that there is a zone of optimal values of the above parameters, at which a sufficiently high sorting accuracy is achieved, high specific productivity, and particle damage is relatively small.
The productivity of the sorting surface under the condition of continuous and uniform operation of the machine can be approximately determined by the general equation for machines of continuous transport, [9].
With increased specific productivity, particles go along the sorting surface in more than one layer and the probability of particles passing through the working holes is low. Damage is reduced due to the reduced likelihood of particles meeting with elements of the sorting surface. To obtain high quality screening, it is necessary to strive to ensure that the particles are located on the sorting surface with a height of one elementary layer. In this case, the sorting surface will work under optimal loading conditions.
In order to improve the quality of products, the parameters and modes of the proposed sorting device are justified. The sorting device consists of a drum formed by disks, on the circumference of which the threads are pulled, rotated by an electric motor and mounted on a frame (Figure 5).
Figure 5 - Scheme of the vacuum screening machine:
1,3,10 - shut-off and controlled valve; 2.4 - pumps line with overflow neck; 12 - desublimator; 13 - mass for water and air; 5 - vacuum gauge; 6 - vacuum pipe- spectrometer; 14 - vacuum gauge; 15 - pressure switch; line; 7 - leak detector; 8.9, 19 - rotary lock; 11 - drain 16 - water ring vacuum pump; 17 - vacuum sorting
chamber; 18 - spray nozzle manifold ultrasonic water and air cleaning.
The drum, rotating in the supports fixed on the frame, sorts through the gaps between the threads the incoming sliced potato particles from the loading tray into cuttings and standard-sized cubes moved by the conveyors of cuttings and standard blocks. The calibrating surface divides the pile into two fractions -"passage" and "descent", trimmings and non-standard particles pass through the holes, standard ones leave the surface (parallel separation).
The use of this design solves the following technical problems:
• the coefficient of sorting accuracy increases with a relatively short drum length, since the shape of the sorting holes is slit-shaped, and they are located along the direction of movement of the components of the pile of particles, which ensures rapid sifting of the cuttings;
• line productivity increases, the quality of the final product improves.
These advantages are achieved by the fact that the device for sorting is made in the form of a cylindrical drum mounted at an angle to the horizontal plane. In addition to the location of the drum, there is another solution to the problem of contamination of the filaments - the installation of high - pressure water nozzles, [10].
This design is preferred due to:
S - simplicity and reliability of the design;
S - the rotary mechanism of the injectors allows you to adjust the direction of the water flow;
S high pressure makes it possible to quickly clean the threads (in contrast to the mechanical cleaning option) and saves water;
S wide spray angle eliminates the possibility of ineffective cleaning of the threads.
Conclusions, results, discussion
The operation of the equipment in the complex should include:
S Continuous operation of the entire line and each piece of equipment separately.
S A small number of attendants.
S A systematic approach to quality control, production hygiene, and maintenance of each piece of equipment in the complex.
S Manufacturability of equipment.
The use of a complex scheme of using equipment requires the development and creation of machines of complex action (MCD) on the example of a vacuum-sorting and drying machine, with automated control being carried out, monotonous manual labor is minimized, and overall productivity is increased. The use of MCD in the production of potato products according to a complex scheme will ensure the smallest losses, which contributes, with sufficient availability of raw materials, to a more intensive increase in the production of a range of food products from potatoes.
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