Thursday, September 5, 2024
Vecoplan is consistently advancing its solutions to enhance the efficiency of shredding processes, as evidenced by several innovative technical features. A key focus for the company is the growing emphasis on digitalisation. By leveraging data, operators can reliably monitor processes and automate work steps, reducing the risk of errors typically associated with manual shredder settings. This not only optimises machine performance but also prolongs the lifespan of the equipment.
“Many machine parameters that workers formerly set manually can now be managed automatically,” says Paul Mockenhaupt, who is responsible for digitalisation at Vecoplan. “For us it’s becoming more and more important to equip our machines with intelligence so that customers have better support.” With this in mind, Mockenhaupt and his team are developing technical features to improve shredding processes. One example is an electrically powered ram.
Electrical means energy-efficient
“We’ve equipped our new electrically powered ram with highly dynamic ball screw drives,” explains Vecoplan’s developer. “Thanks to the high efficiency of these components, users benefit from excellent energy savings.” An electrical system, in contrast to a hydraulic one, does not need oil that can contaminate the output material. This is becoming more and more important to customers. Another key aspect is robust design. An electrical drive requires fewer mechanical parts, and that means less wear.
“Also, as compared to a hydraulic ram, our new solution can be better controlled. Users can set the torque, and thus the pressure applied to the material, very exactly,” says Mockenhaupt. The electrical ram steadily moves the input towards the rotor on the shaft. The new variant is also more dynamic and thus faster, which raises the throughput.
Powerful direct drive
Vecoplan can optionally equip its shredders with its more powerful and efficient HiTorc direct drive, which operates economically even at higher throughputs. “A controller integrated in the frequency converter ensures that the optimum torque is available at the rotor shaft at all times and in all operating conditions,” says Mockenhaupt. As a result, the drive is extremely energy-efficient. What is more, this purely electrical solution requires no clutches, belt drives or flywheels, which means that maintenance costs are much lower. “And because mechanical components are eliminated, the mass moments of inertia in the entire drive system are also significantly reduced,” adds Mockenhaupt. “The high availability of the torque enables a problem-free start-up under load, i.e., when the shredding area is full.”
The fully automated control system continuously analyzes speed and evaluates electrical current to detect potential machine overload early in the shredding process. If foreign material is detected, the rotor shaft halts within milliseconds, protecting critical components from damage. After a brief counter-rotation, the Vecoplan drive resumes in the required direction within seconds.
Additionally, the synchronous motor delivers remarkable efficiency. Shredders equipped with this technology can save up to 40% more energy compared to those with electromechanical drives, and up to 60% compared to hydraulic-driven shredders.
Smart detection of extraneous material
Another new feature is smart, vibration-based detection of tramp material. This allows Vecoplan to keep an eye on the customer’s material and safely avoid damage to the machine. Operators can take advantage of a user-friendly measurement procedure. “Our solution is self-teaching,” says Vecoplan’s expert. When the shredder starts, sensors record all the important information, such as material properties, cutting grades and cutting geometry. The tramp material detection system adapts to the required sensitivity of the given input and environmental conditions. Operators previously had to do this manually, and it was time-consuming. Now, when the parameters change, it is only necessary to call up new settings. This can even be done remotely. “Thanks to our new material detection system, users have more than just a robust shredder. If required, the machine can even detect small stones and immediately stop without intervention from the operator,” says Mockenhaupt.
“We get feedback from the sensors about the shredding process and learn how the shredder is performing. If necessary, we can optimise the process.” On request by the customer, Vecoplan will also retrofit existing machinery with the smart detection system.
Quick setting of the ideal cutting gap
Vecoplan now also offers automatic adjustment of the counter knives. “As a rule, the workers in each shift have to manually adjust the counter knives in order to correct changes in the cutting gap that can occur in operation,” explains Mockenhaupt.
When the gap is too large, the shredder consumes more energy as the material is crushed rather than sliced, leading to lower-than-expected output quality. Adjusting the machine manually by a worker can take anywhere from 15 to 30 minutes.“Our automatic solution reduces the time needed by a factor of ten – without requiring anyone to intervene,” says Mockenhaupt.
When the shredder runs empty, the counter knives are automatically reset, ensuring continuous and efficient operation throughout the day. This feature is particularly beneficial for customers looking to maintain high machine performance. The result is consistent output quality, improved energy efficiency, and significantly reduced wear on the shredder, leading to an extended lifespan.
. “Correct manual adjustment of the counter knives also requires considerable know-how and a special feel on the part of the operator,” adds Vecoplan’s expert. “Our automatic counter knives are a true game changer. They set the gap exactly right, over and over, regardless of an employee’s knowledge and skill.”
Cooling with minimal amounts of water
Thermally sensitive plastics can soften from the heat produced at the rotor during shredding and keep the material from achieving the required output quality. Cooling water can prevent this. However, it is important to apply the right amounts. Too much water can adversely affect subsequent processes.
Vecoplan has solved this by developing a minimum-quantity cooling system. “We can set the amount of cooling water at the right point by measuring the temperature of the material,” says Mockenhaupt. “Adjustable temperature limits allow us to exactly control the water supply.” The cooling water is vapourised and dissipated. If new material is fed to the shredder, there is no need to make changes to the machine itself. One only has to change the recipe for the new material. Adjustable temperature limits give users great flexibility in the choice of materials to be processed. All they need is a water connection. Expensive auxiliary equipment is not necessary. Operators can take advantage of the Vecoplan Smart Center (VSC) to monitor and record operating costs, among other factors.
Read more news on: Vecoplan, woodworking machinery, shredder, energy industry, wood dust, wood chips
Get more updates on American woodworking industry through: www.woodandpanel.us
Tags: #1 woodworking news, best wood magazine, best wood news, digitalisation, shredder news, shredding industry news, shredding technology, vecoplan, vecoplan news, wood, wood and panel, wood chip industry news, woodworking, woodworking and manufacturing, woodworking and processing, woodworking industry, woodworking machinery news
Comments: