Optimizing the operating trajectory of a flat scraper for manure cleaning within a fermentation tank requires focusing on three core objectives: reducing unnecessary friction, balancing load distribution, and adapting to material characteristics. Through coordinated adjustments to trajectory shape, motion parameters, and structural adaptation, wear can be significantly reduced and equipment lifespan extended.
Trajectory shape optimization must consider the fermentation tank's geometry and material characteristics. Traditional linear reciprocating trajectories tend to create scraping blind spots in tank corners, leading to localized material accumulation and increased concentrated stress on the scraper edges. Using spiraling or biomimetic curved trajectories can achieve more uniform coverage. For example, a progressive spiral mimicking a snail's crawling trajectory allows the scraper to gradually cover the entire tank during rotation, avoiding repeated scraping of the same area. This trajectory design also guides material flow towards the discharge port, reducing reverse friction caused by material backflow.
Dynamic adjustment of motion parameters is crucial for reducing wear. The scraper's rotational speed and linear movement speed need to be adjusted in real-time according to the material viscosity. High-viscosity materials require reduced rotational speed to decrease shear force, while increasing linear movement speed to maintain scraping efficiency; low-viscosity materials can be handled with the opposite strategy. By integrating a pressure sensor into the drive system, the contact pressure between the scraper and the tank wall can be monitored in real time. When the pressure exceeds a threshold, the rotation speed is automatically reduced or the trajectory radius is adjusted to prevent damage to the tank wall or scraper surface due to excessive compression.
Adaptive improvements to the scraper structure significantly enhance wear resistance. A segmented scraper design breaks down the overall scraper into multiple independent modules, each with individually adjustable angles and pressures. This adapts to irregular tank surfaces and prevents localized wear from spreading to the entire scraper. Wear-resistant alloy strips or ceramic plates are embedded in the scraper edges to form a hard protective layer at critical contact points, extending service life. Some designs also incorporate elastic buffer structures, such as spring-supported floating scrapers, which absorb impact through elastic deformation, reducing wear from rigid collisions.
Trajectory planning must fully consider the cleaning needs of the fermentation tank. Traditional fixed trajectories easily create regular scratches on the tank wall, becoming a breeding ground for microorganisms. By using a randomized trajectory algorithm, the scraper's path varies slightly each time, avoiding overlapping scratches and reducing cleaning difficulty. Combining pulse scraping technology with brief increases in scraping pressure at specific locations allows for more thorough removal of stubborn residues and reduces wear accumulation caused by repeated scraping of the same area.
Multiple scrapers working in tandem can distribute load pressure during manure cleaning. In large fermenters, multiple sets of scrapers are symmetrically distributed, achieving load balance through synchronous or asynchronous movement. For example, two sets of scrapers work alternately, with one set scraping while the other remains non-contact, ensuring continuous operation while providing cooling and self-cleaning time for the scrapers, reducing material fatigue caused by prolonged high-temperature operation. This design also reduces the size and weight of individual scraper sets, decreasing the load on the drive system.
Trajectory optimization needs to be deeply integrated with the fermentation process. In solid-state fermentation or high-density cultivation scenarios, the morphology and distribution of materials dynamically change with the fermentation process, requiring the scraper trajectory to be adaptive. By arranging multiple sensors inside the tank to monitor the material height, density, and hardness distribution in real time, the control system can dynamically adjust the scraper trajectory based on feedback data, ensuring a gentler scraping method in the densest areas and increased efficiency in looser areas, achieving a balance between process requirements and equipment protection. Optimizing the flat scraper's operating trajectory is a complex system engineering project, requiring comprehensive design across multiple dimensions, including trajectory shape, motion parameters, structural adaptation, cleaning requirements, load distribution, and process integration. By introducing intelligent control technology and new materials, the scraper can meet fermentation process requirements while minimizing wear, thereby improving the stability and economy of equipment operation.
