平菇发酵料装料接种一体机关键装置的设计与试验

    Design and experiment of the key components of charging and inoculating integrated machine for Pleurotus ostreatus

    • 摘要: 针对当前平菇菌棒生产中的装料、接种单机作业效率低、稳定性差、用工多等难题,该研究结合平菇栽培料诱导灭菌发酵工艺与中心孔接种工艺,设计了一种适应玉米芯颗粒菌种的平菇发酵料装料接种一体机,整机主要由装料装置、窝口装置和接种装置等组成。首先根据菌棒制作中的装料量与接种量要求对整机的关键部件进行设计,确定装料绞龙、窝口槽型凸轮和接种凸轮等零部件的结构参数,然后以绞龙转速、绞龙直径和绞龙螺距为影响因素,装料生产率和装料密度为响应指标,通过响应曲面方法分析各因素交互作用影响,对回归模型进行多目标优化,得出平菇发酵料装料接种一体机装料质量的最优组合为:绞龙转速191.94 r/min,绞龙直径133.22 mm,绞龙螺距100.00 mm,此时,装料生产率723袋/h,装料密度537.27 kg/m3。对优化参数进行生产验证,测得生产率为726袋/h,装料密度为536.25 kg/m3,与优化值相对误差分别为0.42%和0.19%。同时,测得接种电机转速在120 r/min时的接种量为132.33 g,接种变异系数为1.19%,满足发酵料中心孔菌种量不少于装料量5%的生产要求,接种装置的平均接种深度为242.5 mm,接种深度的变异系数为1.05%。与单机菌棒制作设备相比,平菇发酵料装料接种一体机生产率提高3倍,时间缩短2.4 倍,人数减少4人,节省2道作业工序,满足北方地区平菇发酵料机械化生产对装备的需求。

       

      Abstract: Pleurotus ostreatus has been one of the most widely cultivated and the largest edible fungi in China. Global production has been growing rapidly, due to simple cultivation, low cost, quick effect, high yield, and short cycle. According to the statistics of the China Edible Mushroom Association, the output of Pleurotus ostreatus in 2020 was 6.8647 million tons, accounting for 17.45% of the total output of edible fungi, indicating the third-largest cultivar in China. However, there is still a great challenge on the efficiency and stability in the current production of oyster mushroom cobs combined with the induction, sterilization, and fermentation of Pleurotus ostreatus cultivation material and the central-hole inoculation. Taking a corncob particle as the Pleurotus ostreatus fermentation material, this study aims to develop a strain charging and inoculating machine, particularly for the higher efficiency of single machine operation, high stability, and full automation. Three devices were mainly composed of a charger, a nest, and an inoculation device. The key components of the whole machine were designed, according to the requirements of the charging quality and inoculation amount in the production of bacterial sticks, thereby determining the structural parameters of the charging auger, the socket groove cam, and the inoculation cam. A response surface method was used to optimize the test factors, where the diameter of the auger and the pitch of the auger were the influencing factors, and the charging productivity and density were the response indicators. A regression mathematical model was established for the charging productivity and density. The response value of the rotation speed of the auger was obtained to determine the most significant impact. Furthermore, the inoculum amount of bacteria was measured under different inoculation electromechanical speeds. As such, the inoculum amount was 132.33 g, and the inoculation variation coefficient was 1.19 %, when the inoculation motor speed was 120 r/min, which satisfied the number of bacteria in the center hole of the fermented material. The production requirement was measured to be 242.5 mm less than 5% of the charge and the average inoculation depth of the inoculation unit. Multi-objective optimization of the regression model was carried out to further verify the charging performance of the equipment. The optimal structural parameters of the charging device were obtained as follows: the auger rotation speed of 191.94 r/min, auger diameter 133.22 mm, auger pitch 100.00 mm, while the charging productivity was 723 bags/h, the charging density was 537.27 kg/m3, and the charging mass was 2.42 kg. The optimized all-in-one and stand-alone machine was verified for production. It was found that the charging productivity of the all-in-one machine was 726 bags/h, the charging density was 536.25 kg/m3, the coefficient of variation of the charging quality was 0.82%, and the coefficient of variation of the inoculation amount was 0.92%, the coefficient of variation of the inoculation depth was 1.05%, the mouth of the fungus bag was firm and flat, while the folds were uniform, and the nest has no leaking bags. This key component can fully meet the equipment demand for the mechanized production of oyster mushroom fermentation materials in northern regions.

       

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