Description:TECHNICAL FIELD
[0001] The present invention relates to a debarking machine designed for the efficient and uniform removal of bark from wooden logs. This machine is particularly suited for preparing logs for subsequent use in plywood manufacturing and other industrial applications requiring clean, debarked wood.
BACKGROUND ART
[0002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0003] Debarking is an essential preliminary step in the processing of wooden logs for various industrial applications, particularly in the production of plywood, paper, and other wood-based products. The process involves the removal of the outer bark from the logs, which serves to prepare the wood for further processing, such as cutting, peeling, or chipping. Bark is generally undesirable in these processes due to its irregular texture, variability in thickness, and the presence of contaminants that can affect the quality of the final product. Consequently, effective and efficient debarking is critical to ensuring that the underlying wood is clean, smooth, and ready for subsequent processing.
[0004] Traditional Methods of Debarking: Historically, debarking was performed manually, using simple tools like axes, draw knives, or chisels. This manual debarking was labor-intensive, slow, and often resulted in inconsistent bark removal. The quality of the debarking largely depended on the skill and experience of the worker, leading to variability in the finished logs. Additionally, manual debarking posed significant risks to the workers, including physical strain, injury from sharp tools, and exposure to harsh environmental conditions.
[0005] As industrial demand for wood products grew, so did the need for more efficient and mechanized debarking methods. Early mechanized debarking machines were developed in response to this need, employing various techniques such as flailing, grinding, and peeling to remove bark from logs. While these machines represented a significant improvement over manual methods, they still had several limitations. For instance, many early debarking machines were designed to handle only specific types of logs, making them less versatile and adaptable to different species of wood. Furthermore, these machines often caused damage to the underlying wood, especially when the logs were not uniformly shaped or when the bark was particularly thick or tough.
[0006] Challenges in Modern Debarking: In modern industrial settings, the debarking process faces several challenges, primarily related to efficiency, uniformity, and the preservation of wood integrity. As demand for high-quality wood products has increased, so has the need for debarking machines that can consistently produce clean, smooth logs with minimal damage. The key challenges include:
[0007] Variability in Log Characteristics: Logs vary widely in terms of species, size, shape, and bark thickness. This variability makes it difficult to design a one-size-fits-all debarking machine. For example, some species have thin, easily removable bark, while others have thick, fibrous bark that adheres tightly to the wood. The diameter and shape of the logs also vary, with some logs being relatively straight and uniform, while others are more irregular and tapered. A debarking machine must be capable of handling this diversity without compromising the quality of the debarking process.
[0008] Damage to Underlying Wood: One of the primary concerns in the debarking process is the potential for damage to the underlying wood. Aggressive debarking methods can gouge or scar the wood, reducing its value and suitability for further processing. This is particularly problematic in industries where the appearance and integrity of the wood are critical, such as in plywood manufacturing or the production of high-grade lumber. The challenge lies in designing a machine that can remove the bark effectively without damaging the wood beneath it.
[0009] Efficiency and output: In large-scale industrial operations, the speed and efficiency of the debarking process is crucial. A debarking machine must be able to process a high volume of logs in a relatively short amount of time to meet production demands. However, increasing the speed of debarking can sometimes compromise the quality of the process, leading to incomplete bark removal or damage to the wood. Balancing speed and quality are therefore a key challenge in the design of debarking machines.
[0010] Waste Management: The removal of bark generates a significant amount of waste material, which must be managed effectively to maintain a clean and efficient working environment. In some cases, the bark can be repurposed for other uses, such as mulch or biofuel, but this requires additional processing steps. Efficient waste management systems are therefore an important consideration in the design of debarking machines.
[0011] Automation and Control: With the advent of modern technology, there has been a growing trend towards the automation of industrial processes, including debarking. Automated debarking machines can reduce the need for manual intervention, improving safety and consistency. However, automation introduces its own set of challenges, particularly in terms of control and precision. The machine must be able to adapt to different log characteristics in real time, adjusting the debarking process as needed to ensure optimal results.
[0012] Existing Debarking Technologies: Over the years, several types of debarking machines have been developed, each employing different mechanisms and techniques to remove bark from logs. Some of the most common types of debarking machines include:
[0013] Ring Debarkers: Ring debarkers use a series of rotating knives or knifes arranged in a circular configuration (the "ring") to strip the bark from logs as they pass through the machine. The knives are typically adjustable to accommodate logs of different diameters. Ring debarkers are widely used in the industry due to their ability to handle large volumes of logs with relatively consistent results. However, they can be prone to damaging the wood, particularly if the knives are not properly adjusted or if the logs are irregular in shape.
[0014] Drum Debarkers: Drum debarkers consist of a large, rollers with internal ribs or other abrasive surfaces. Logs are fed into the drum and tumbled around as it rotates, causing the bark to be stripped away by the friction between the logs and the drum's interior. Drum debarkers are particularly effective for processing logs with thick or tough bark, but they can be less precise than other methods, sometimes resulting in incomplete bark removal or damage to the wood.
[0015] Chain Flail Debarkers: Chain flail debarkers use chains or flails attached to rollers to beat the bark off the logs. The chains are typically flexible, allowing them to conform to the shape of the logs and providing a degree of versatility in handling different log sizes and shapes. However, chain flail debarkers can be quite aggressive, increasing the risk of damage to the underlying wood, especially if the logs are not uniformly shaped.
[0016] Rosser Head Debarkers: Rosser head debarkers use a rotating cutter head mounted on a pivoting arm to remove bark from stationary logs. The cutter head moves along the length of the log, removing the bark in a series of passes. Rosser head debarkers are known for their precision and ability to handle logs with irregular shapes, but they tend to be slower than other types of debarkers, making them less suitable for high-volume operations.
[0017] Water Jet Debarkers: Water jet debarkers use high-pressure water jets to blast the bark off the logs. This method is particularly gentle on the wood, reducing the risk of damage, but it can be less effective on logs with very thick or tightly adhered bark. Water jet debarkers also require significant amounts of water, which can be a limiting factor in some industrial settings.
[0018] Limitations of Existing Technologies: While the existing debarking technologies have improved the efficiency and consistency of the debarking process compared to manual methods, they still have several limitations that affect their performance and versatility. Some of the key limitations include:
[0019] Inconsistent Bark Removal: Many debarking machines struggle to achieve consistent bark removal across logs of different sizes, shapes, and species. This inconsistency can result in logs with patches of remaining bark or areas where the wood has been damaged by overly aggressive debarking. This is particularly problematic in industries where uniformity and quality are critical, such as plywood manufacturing.
[0020] Damage to Wood: As mentioned earlier, one of the main challenges in debarking is avoiding damage to the underlying wood. Many existing debarking machines, particularly those that use aggressive methods like chain flails or high-pressure water jets, can cause gouges, scars, or other damage to the wood. This not only reduces the value of the logs but also increases the need for subsequent processing steps to repair or remove the damaged areas.
[0021] Limited Adaptability: Many debarking machines are designed to handle specific types of logs, making them less adaptable to different species, sizes, or shapes. For example, a machine designed to debark softwood logs may not perform well with hardwood logs, which typically have tougher, more tightly adhered bark. Similarly, machines that are optimized for straight, uniform logs may struggle with irregularly shaped or tapered logs. This lack of adaptability can limit the versatility of the debarking machine and reduce its overall efficiency.
[0022] Complexity and Maintenance: Some debarking machines, particularly those with more complex mechanisms or automated control systems, can be difficult to maintain and repair. Regular maintenance is essential to ensure that the machine operates efficiently and consistently, but it can be time-consuming and costly. Additionally, the complexity of some machines can make them more prone to breakdowns or malfunctions, further reducing their reliability and productivity.
[0023] Environmental Considerations: Debarking processes, particularly those that use high-pressure water jets or other abrasive methods, can generate significant amounts of waste and require substantial amounts of water or energy. Managing this waste and ensuring that the debarking process is environmentally sustainable can be challenging, particularly in large-scale industrial operations.
[0024] Need for an Improved Debarking Machine: Given the limitations of existing debarking technologies, there is a clear need for an improved debarking machine that can address these challenges and provide more consistent, efficient, and damage-free bark removal. Such a machine would need to incorporate several key features and innovations, including:
[0025] Versatility and Adaptability: The ideal debarking machine should be capable of handling a wide range of log species, sizes, and shapes without compromising the quality of the debarking process. This would require a debarking mechanism that can be easily adjusted or adapted to different log characteristics, ensuring consistent results across a variety of conditions.
[0026] Precision and Control: To avoid damage to the underlying wood, the debarking machine should provide precise control over the debarking process, allowing the operator to adjust the intensity or aggressiveness of the bark removal as needed. This could be achieved through advanced automation and control systems that monitor the log characteristics in real-time and adjust the debarking parameters accordingly.
[0027] Efficiency and Output: The debarking machine should be capable of processing a high volume of logs quickly and efficiently, without compromising the quality of the debarking. This would require a robust and reliable design that minimizes downtime and maintenance requirements, as well as a waste management system that effectively handles the removed bark and other debris.
[0028] Durability and Reliability: To withstand the harsh conditions of industrial environments, the debarking machine should be built from high-quality materials and components that are resistant to wear and tear. The machine should also be designed for easy maintenance and repair, with components that can be quickly replaced or serviced as needed.
[0029] Environmental Sustainability: The debarking process should be environmentally sustainable, minimizing waste generation and resource consumption. This could involve the use of energy-efficient motors and systems, as well as waste management solutions that repurpose the removed bark for other uses, such as biofuel or mulch.
[0030] The present invention addresses the need for an improved debarking machine that overcomes the limitations of existing technologies. By incorporating innovative features and advanced design elements, the machine provides consistent, efficient, and damage-free bark removal across a wide range of log species, sizes, and shapes. This makes it ideally suited for use in industrial applications such as plywood manufacturing, where quality, efficiency, and reliability are paramount. The machine's versatility, precision, and durability ensure that it can meet the demands of modern wood processing operations while minimizing environmental impact and reducing operational costs.
[0031] All publications herein are incorporated by reference to the same extent as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.
OBJECTS OF THE INVENTION
[0032] The principal object of the present invention is to overcome the disadvantages of the prior art.
[0033] Another object of the present invention is to provide a debarking machine capable of efficiently removing bark from wooden logs, ensuring high output suitable for large-scale industrial applications like plywood manufacturing.
[0034] Another object of the present invention is to achieve consistent and uniform debarking across logs of varying sizes and species, ensuring that the finished logs have a smooth and clean surface suitable for further processing.
[0035] Another object of the present invention is to minimize the risk of damage to the underlying wood during the debarking process, preserving the integrity and quality of the logs.
[0036] Another object of the present invention is to provide a debarking machine with a robust construction and advanced components, such as the 2-stage planetary gearbox and reverse knife clamping system, to ensure long-term durability and reliable operation under heavy industrial use.
[0037] Yet another object of the present invention is to improve the log handling process through the use of uniquely designed rollers with a zigzag pattern, ensuring secure and efficient movement of logs through the machine.
SUMMARY
[0038] The present invention provides a debarking machine that addresses the limitations of traditional methods by incorporating a unique design that ensures uniform debarking while minimizing damage to the logs. The machine is equipped with advanced mechanisms for log handling, bark removal, and waste management, making it ideal for industrial applications such as plywood manufacturing. Key features include a uniquely designed gearbox mounting that balances structural loads and impacts, a 2-stage planetary gearbox with a high safety factor, a specially designed knife holder with reverse knife clamping, and a linear motion cylindrical sliding system for precise control of log movement.
[0039] Construction:
[0040] Frame and Housing: The debarking machine is built on a robust frame that supports all operational components. The housing is designed to contain and guide logs through the debarking process. The frame and housing are fabricated with high carbon normalized plates, ensuring structural integrity and durability. The machining accuracy of the body is within ±20 microns, ensuring no manufacturing defects or errors.
[0041] Log Feed System: The rollers designed to ensure the steady and controlled movement of logs into the debarking section. The rollers feature a unique zigzag design with extra length, which facilitates easy handling of logs and increases productivity. The roller bearing blocks use spherical self-aligned bearings with seals on both ends, enclosed in precisely machined brackets. The design incorporates both single and double roller bearing blocks to enhance log handling efficiency.
[0042] Debarking Mechanism: The core debarking mechanism consists of rollers and knive that effectively remove bark from the surface of the logs. The backup system accommodates logs of various diameter through hydraulic system. A specially designed knife holder with reverse knife clamping increases knife strength, resulting in load-free rounding of wooden logs and reducing the risk of damage to the knife and machine. The knife holder’s reverse clamping system further enhances the durability of the knife and machine.
[0043] Power and Control System: The machine is powered by an electric motor with an integrated control system. The power system includes a 2-stage planetary gearbox, uniquely designed to withstand all thrust loads and impacts. The gearbox has a safety factor three times higher than normal gearboxes, ensuring long-term reliability and performance. A unique gearbox mounting is designed to balance the entire structural load, preventing damage to the gearbox and machine.
[0044] Linear Motion Cylindrical Sliding System: This system uses hardened tempered, hard chrome rods with a hardness of HRC 60, ensuring durability and precision. The linear motion system includes a double-row, single-piece design that enables precise control of up/down and right/left movement of the logs. The hydraulic power pack balances the pressure in both cylinders, enhancing machine life and maintaining consistent linear movement for even log rounding.
[0045] The sliding system incorporates a high-quality oil pump that automatically lubricates the bushes within the system, ensuring consistent and smooth operation while significantly reducing the risk of friction-related wear and tear. The bushes are made from a world-standard high-quality material, AB2, known for its excellent wear resistance, low friction properties, and high load-bearing capacity. This choice of material enhances the overall durability and longevity of the sliding system, making it suitable for heavy-duty industrial applications.
[0046] The system is engineered to perform reliably for up to 2 million cycles, depending on the operating environment, thereby providing long-term performance with minimal maintenance requirements. Additionally, the hardened and tempered chrome rods used in the sliding system have a hardness of HRC 60, making them exceptionally tough and resistant to impact. These rods are designed to withstand even harsh impacts, such as being struck by an iron hammer, without sustaining any damage, ensuring the machine's continued precision and reliability.
[0047] Operation:
[0048] Log Loading: Logs are loaded onto the rollers, which transports them into the debarking section. The log feed system ensures controlled and steady movement, reducing the risk of jamming or misalignment.
[0049] Bark Removal: As the logs pass through the debarking section, the knife strip off the bark, ensuring a clean and smooth log surface. The adjustable knifes ensure uniform bark removal across logs of varying diameters.
[0050] Waste Management: The removed bark is collected and conveyed away from the machine through a waste disposal system, ensuring a clean working environment. This system enhances the efficiency of the debarking process by preventing the accumulation of waste materials.
[0051] Advantages:
[0052] Efficiency: The machine provides a high output, making it suitable for large-scale plywood manufacturing operations. The design ensures consistent operation with minimal downtime.
[0053] Uniformity: The adjustable knife and precision control systems ensure consistent bark removal, resulting in uniformly debarked logs. This uniformity is crucial for subsequent processing in plywood production.
[0054] Damage Reduction: The machine's design minimizes the risk of damage to the wood, preserving the integrity of the logs. The reverse knife clamping system and unique gearbox mounting contribute to the machine's ability to handle logs without causing damage.
[0055] Ease of Use: The machine’s automated control system simplifies operation, reducing the need for manual intervention. The high-quality oil pump provides timely lubrication to the linear sliding system, ensuring smooth and maintenance-free operation.
[0056] Durability: The robust construction, high-precision machining, and advanced materials used in the machine ensure long-term durability and reliability. The machine is designed to withstand the harsh conditions of industrial environments.
[0057] These and other features will become apparent from the following detailed description of illustrative embodiments thereof, which is to be read in connection with the accompanying drawings. While the invention has been described and shown with reference to the preferred embodiment, it will be apparent that variations might be possible that would fall within the scope of the present invention.
BRIEF DESCRIPTION OF DRAWINGS
[0058] The subject matter regarding the invention is particularly pointed out and distinctly claimed in the concluding portion of the specification. The invention, however, both as to organization and method of operation, together with objects, features, and advantages thereof, may best be understood by reference to the following detailed description when read with the accompanying drawings in which:
[0059] Fig. 1 illustrates perspective view of debarking machine.
[0060] Fig. 2 illustrating detailed view of 2-stage planetary gearbox, gearbox mounting system, and knife holder.
[0061] Fig. 3 illustrating detailed view of RR-62 hydraulic cylinder, high-rise bracket, and cylindrical sliding system.
[0062] Fig. 4 illustrating detailed view of double row single piece system to achieve precious movement.
[0063] Fig. 5 illustrating detailed view of planetary gearbox, gearbox mounting and double roller bearing block.
DETAILED DESCRIPTION OF THE INVENTION
[0064] While the present invention is described herein by way of example using embodiments and illustrative drawings, those skilled in the art will recognize that the invention is not limited to the embodiments of drawing or drawings described and are not intended to represent the scale of the various components. Further, some components that may form a part of the invention may not be illustrated in certain figures, for ease of illustration, and such omissions do not limit the embodiments outlined in any way. It should be understood that the drawings and the detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the scope of the present invention as defined by the appended claim.
[0065] As used throughout this description, the word "may" be used in a permissive sense (i.e. meaning having the potential to), rather than the mandatory sense, (i.e. meaning must). Further, the words "a" or "an" mean "at least one” and the word “plurality” means “one or more” unless otherwise mentioned. Furthermore, the terminology and phraseology used herein are solely used for descriptive purposes and should not be construed as limiting in scope. Language such as "including," "comprising," "having," "containing," or "involving," and variations thereof, is intended to be broad and encompass the subject matter listed thereafter, equivalents, and additional subject matter not recited, and is not intended to exclude other additives, components, integers, or steps. Likewise, the term "comprising" is considered synonymous with the terms "including" or "containing" for applicable legal purposes. Any discussion of documents acts, materials, devices, articles, and the like are included in the specification solely for the purpose of providing a context for the present invention. It is not suggested or represented that any or all these matters form part of the prior art base or were common general knowledge in the field relevant to the present invention.
[0066] In this disclosure, whenever a composition or an element or a group of elements is preceded with the transitional phrase “comprising”, it is understood that we also contemplate the same composition, element, or group of elements with transitional phrases “consisting of”, “consisting”, “selected from the group of consisting of, “including”, or “is” preceding the recitation of the composition, element or group of elements and vice versa.
[0067] The present invention is described hereinafter by various embodiments with reference to the accompanying drawing, wherein reference numerals used in the accompanying drawing correspond to the like elements throughout the description. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiment set forth herein. Rather, the embodiment is provided so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those skilled in the art. In the following detailed description, numeric values and ranges are provided for various aspects of the implementations described. These values and ranges are to be treated as examples only and are not intended to limit the scope of the claims. In addition, several materials are identified as suitable for various facets of the implementations.
[0068] 1. Overview of the Debarking machine (100):
[0069] The debarking machine (100) of the present invention is designed to address the challenges associated with traditional debarking methods, offering an advanced, efficient, and reliable solution for the removal of bark from wooden logs. This machine is specifically engineered to meet the demands of modern industrial applications, such as plywood manufacturing, where consistency, efficiency, and the preservation of wood integrity are critical.
[0070] The machine comprises several key components, including a robust frame and housing, a log feed system, a debarking mechanism with adjustable, a power and control system, and a waste management system. Additionally, the machine features several innovative design elements, such as a unique gearbox mounting system (106), a 2-stage planetary gearbox (104), a specially designed knife holder (108) with reverse knife clamping, and a linear motion cylindrical sliding system (116). These features collectively ensure that the machine operates with high efficiency, precision, and durability, while minimizing the risk of damage to the underlying wood.
[0071] 2. Construction:
[0072] 2.1 Frame and Housing: The debarking machine (100) is built on a robust frame that provides structural support for all operational components. The frame is constructed from high carbon steel plates, ensuring exceptional strength and durability. The plates are machined with an accuracy of ±20 microns, which guarantees a precise fit and alignment of all components, minimizing the risk of manufacturing defects and ensuring long-term reliability.
[0073] The housing of the machine is designed to contain and guide logs through the debarking process, providing a controlled environment in which the logs are processed. The housing is equipped with access panels and inspection windows, allowing for easy monitoring and maintenance of the internal components. The robust construction of the frame and housing ensures that the machine can withstand the rigors of industrial use, including exposure to harsh environmental conditions and heavy workloads.
[0074] 2.2 Log Feed System: The log feed system is a critical component of the debarking machine (100), responsible for the steady and controlled movement of logs into the debarking section. This system comprises rollers, which work together to transport logs smoothly and efficiently.
[0075] The rollers in the log feed system are designed with a unique zigzag pattern and extended length, which facilitates the easy handling of logs of various sizes and shapes. The zigzag design ensures that the logs are securely gripped and guided through the machine, reducing the risk of slippage or misalignment. The extended length of the rollers allows the machine to accommodate logs, increasing its versatility and productivity.
[0076] The rollers are mounted into single and double roller bearing blocks (110), which contain spherical roller self-aligned bearings with seals on both ends. These bearings are enclosed in precisely machined brackets, ensuring smooth and stable movement of the logs. The self-aligned bearings are particularly beneficial for accommodating any slight variations in the log’s shape or size, preventing undue stress on the rollers and extending their lifespan.
[0077] 2.3 Debarking Mechanism: The core of the debarking machine (100) is the debarking mechanism, which is responsible for the removal of bark from the surface of the logs. This mechanism consists of adjustable knife to accommodate logs of various diameters. The knifes are designed to effectively strip off the bark while minimizing the risk of damage to the underlying wood.
[0078] 2.3.1 2-stage planetary gearbox (104): The rollers are powered by a 2-stage planetary gearbox (104), which is uniquely designed to withstand all thrust loads and impacts encountered during the debarking process. The safety factor of this gearbox is three times higher than that of standard gearboxes, providing enhanced durability and reliability. The gearbox is mounted in a manner that balances the structural loads and impacts, ensuring zero damage to both the gearbox and the machine during operation. This innovative gearbox design not only extends the life of the machine but also reduces the need for frequent maintenance.
[0079] 2.3.2 Knife holder (108) with Reverse Knife Clamping: The knife holder (108) in the debarking mechanism is specially designed to enhance the strength and durability of the knifes. It features a reverse knife clamping system, which increases the clamping force on the knifes, reducing the likelihood of knife movement or slippage during operation. This reverse clamping system also contributes to load-free rounding of the wooden logs, ensuring a smooth and even debarking process. By minimizing the stress on the knifes and the machine, this design reduces the risk of damage and extends the lifespan of the components.
[0080] 2.4 Power and Control System: The debarking machine (100) is powered by an electric motor, which drives the roller, knifes and other operational components. The motor is integrated with a sophisticated control system that allows the operator to regulate the speed and operation of the debarking mechanism. The control system is designed to be user-friendly, with intuitive controls and indicators that provide real-time feedback on the machine’s performance.
[0081] 2.4.1 Automated Control System: The automated control system is a key feature of the debarking machine (100), enabling it to adapt to different log characteristics in real time. The system uses sensors to monitor the size, shape, and bark thickness of each log as it enters the machine, and automatically adjusts the position and speed of the roller to ensure optimal bark removal. This level of automation reduces the need for manual intervention, improves consistency, and minimizes the risk of damage to the wood.
[0082] 2.5 Waste Management System: The removal of bark from logs generates a significant amount of waste material, which must be managed efficiently to maintain a clean and productive working environment. The debarking machine (100) is equipped with a waste management system designed to collect and convey the removed bark away from the machine.
[0083] 2.5.1 Bark Collection and Disposal: The waste management system includes a series of conveyors and chutes that transport the removed bark from the debarking section to a designated collection area. The system is designed to handle large volumes of bark efficiently, ensuring that the machine can operate continuously without the need for frequent waste disposal. In some industrial settings, the collected bark can be repurposed for other uses, such as mulch or biofuel, providing an additional benefit to the operator.
[0084] 3. Operation:
[0085] 3.1 Log Loading: The debarking process begins with the loading of logs onto the conveyor belt of the log feed system. The logs are typically loaded manually or using mechanical equipment, such as a log loader or crane. Once the logs are placed on the conveyor belt, they are automatically fed into the debarking section of the machine.
[0086] The conveyor belt and rollers in the log feed system are designed to transport the logs smoothly and steadily into the debarking mechanism. The zigzag design of the rollers ensures that the logs are securely gripped and guided through the machine, reducing the risk of slippage or misalignment.
[0087] 3.2 Bark Removal: As the logs pass through the debarking section, the roller knifes strip off the bark, leaving a clean and smooth surface on the underlying wood. The adjustable knifes are positioned according to the diameter and shape of log, ensuring consistent and efficient bark removal.
[0088] The 2-stage planetary gearbox (104) provides the necessary power and torque to drive the roller, while the reverse knife clamping system ensures that the knifes remain securely in place during operation. The result is a precise and controlled debarking process that minimizes the risk of damage to the wood.
[0089] 3.3 Waste Management: Once the bark has been removed, it is collected and conveyed away from the machine through the waste management system. The system’s conveyors and chutes efficiently transport the removed bark to a designated collection area, where it can be disposed of or repurposed as needed. The automated control system ensures that the waste management process is synchronized with the debarking operation, allowing for continuous and uninterrupted operation.
[0090] 4. Advantages of the Debarking machine (100):
[0091] 4.1 Efficiency: The debarking machine (100) is designed to operate at high output levels, making it suitable for large-scale industrial applications, such as plywood manufacturing. The combination of a robust log feed system, efficient debarking mechanism, and automated control system ensures that the machine can process a high volume of logs in a relatively short amount of time, without compromising the quality of the debarking process.
[0092] 4.2 Uniformity: The roller and automated control system work together to ensure consistent and uniform bark removal, regardless of the size, shape, or species of the logs. This uniformity is particularly important in industries where the appearance and quality of the wood are critical, such as in the production of plywood or high-grade lumber.
[0093] 4.3 Damage Reduction: One of the primary advantages of the debarking machine (100) is its ability to remove bark without damaging the underlying wood. The precise control offered by the automated system, combined with the innovative design of the knife holder (108) and gearbox, minimizes the risk of gouges, scars, or other damage to the wood. This results in higher-quality logs that are better suited for further processing.
[0094] 4.4 Durability and Reliability: The debarking machine (100) is built from high-quality materials and components that are designed to withstand the harsh conditions of industrial use. The robust frame, high carbon steel plates, and precisely machined brackets ensure that the machine can operate reliably over long periods, with minimal maintenance requirements. The 2-stage planetary gearbox (104) and reverse knife clamping system further enhance the durability and longevity of the machine.
[0095] 4.5 Environmental Sustainability: The machine’s waste management system and efficient use of resources contribute to its environmental sustainability. The ability to repurpose removed bark for other uses, such as biofuel, reduces waste and provides an additional environmental benefit. Additionally, the machine’s energy-efficient motor and control system help to minimize energy consumption during operation.
[0096] 5. Additional Features:
[0097] 5.1 Linear Motion Cylindrical sliding system (116): The linear motion cylindrical sliding system (116) is a critical component of the debarking machine (100), providing precise control over the movement of the log feed system. This system uses hardened and tempered hard chrome rods with a hardness of HRC 60, ensuring durability and resistance to wear. The system’s double-row, single-piece design allows for smooth and accurate movement in both the up/down and right/left directions of the hydraulic power backup system enabling precise positioning of the logs for optimal debarking.
[0098] The sliding system incorporates a high-quality oil pump (102) that automatically lubricates the bushes within the system, ensuring consistent and smooth operation while significantly reducing the risk of friction-related wear and tear. The bushes are made from a world-standard high-quality material, AB2, known for its excellent wear resistance, low friction properties, and high load-bearing capacity. This choice of material enhances the overall durability and longevity of the sliding system, making it suitable for heavy-duty industrial applications.
[0099] The system is engineered to perform reliably for up to 2 million cycles, depending on the operating environment, thereby providing long-term performance with minimal maintenance requirements. Additionally, the hardened and tempered chrome rods used in the sliding system have a hardness of HRC 60, making them exceptionally tough and resistant to impact. These rods are designed to withstand even harsh impacts, such as being struck by an iron hammer, without sustaining any damage, ensuring the machine's continued precision and reliability.
[00100] 5.2 Hydraulic Power Pack: The hydraulic power pack is an essential component of the debarking machine (100), responsible for balancing the oil pressure in both hydraulic cylinders (112). This power pack ensures that the machine operates smoothly and efficiently, maintaining linear movement for even log rounding. The power pack also contributes to the machine’s overall durability and reliability by reducing the strain on the hydraulic cylinders (112) and extending their lifespan.
[00101] 5.3 High Rise Bracket: The high-rise bracket is a uniquely designed component that enhances the load-bearing capacity of the debarking machine (100). This bracket is mounted in both the top and side positions, allowing it to evenly distribute the load on the hydraulic cylinders (112). The dual mounting design increases the machine’s ability to withstand heavy loads and impacts, ensuring reliable performance even under demanding conditions.
[00102] The debarking machine (100) described in this invention represents a significant advancement over traditional debarking technologies. With its innovative design features, including the roller, adjustable knife, 2-stage planetary gearbox (104), reverse knife clamping system, and linear motion cylindrical sliding system (116), the machine offers unparalleled efficiency, precision, and durability. The machine’s robust construction, user-friendly control system, and efficient waste management system make it ideally suited for industrial applications such as plywood manufacturing.
[00103] By addressing the limitations of existing debarking methods, this invention provides a solution that not only improves the quality and consistency of the debarking process but also enhances the overall productivity and sustainability of wood processing operations. The machine’s ability to operate efficiently with minimal maintenance requirements ensures that it will be a valuable asset to any wood processing facility, contributing to increased profitability and reduced operational costs.
[00104] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.
[00105] Thus, the scope of the present disclosure is defined by the appended claims and includes both combinations and sub-combinations of the various features described hereinabove as well as variations and modifications thereof, which would occur to persons skilled in the art upon reading the foregoing description.
, Claims:1. A debarking machine (100) comprising:
a robust frame and housing designed to support all operational components and contain logs during the debarking process;
a log feed system, including conveyor belts and rollers, configured to provide steady and controlled movement of logs into the debarking section;
a debarking mechanism with roller, designed to effectively remove bark from the surface of logs of various diameters; and
a power and control system, comprising an electric motor and integrated control unit, configured to regulate the speed and operation of the debarking mechanism.
2. The debarking machine (100) of claim 1, wherein the debarking mechanism includes:
a uniquely designed 2-stage planetary gearbox (104) capable of withstanding all thrust loads and impacts, with a safety factor three times higher than standard gearboxes, thereby ensuring durability and minimal maintenance requirements; and
a specially designed knife holder (108) featuring reverse knife clamping, enhancing knife strength and ensuring load-free rounding of wooden logs, thereby reducing the risk of damage to both the knife and the machine.
3. The debarking machine (100) of claim 1, wherein the log feed system further comprises:
Single and double roller bearing blocks (110) containing spherical roller self-aligned bearings with seals on both ends, enclosed within precisely machined brackets to ensure smooth and stable log handling.
4. The debarking machine (100) of claim 1, wherein the log feed system includes rollers with a unique zigzag design and extended length, facilitating easier handling of logs and improving overall productivity.
5. The debarking machine (100) of claim 1, wherein the gearbox mounting system (106) that balances the structural loads and impacts, ensuring zero damage to the gearbox and machine during operation.
6. The debarking machine (100) of claim 1, wherein the machine is constructed from high carbon plates with machining accuracy within ±20 microns, ensuring a robust structure with no manufacturing defects.
7. The debarking machine (100) of claim 1, further comprising:
an RR-62 hydraulic cylinder (112) equipped with a high-rise bracket (114), uniquely designed to evenly distribute the load on the hydraulic cylinders (112), enhancing the machine's load-bearing capacity due to dual mounting from the top and side.
8. The debarking machine (100) of claim 1, further comprising:
a linear motion cylindrical sliding system (116), utilizing hardened and tempered hard chrome rods with HRC 60 hardness and a double-row, single-piece design to achieve precise control of up/down and right/left movements, ensuring reliable performance for up to 2 million cycles.
9. The debarking machine (100) of claim 9, wherein the linear motion cylindrical sliding system (116) includes a high-quality oil pump (102) that automatically provides lubrication to the bushes of the sliding system, maintaining smooth and consistent operation.
10. The debarking machine (100) of claim 1, further comprising:
a hydraulic power pack system designed to balance the oil pressure in both hydraulic cylinders (112), thereby increasing machine life and maintaining linear movement for even log rounding.
11. The debarking machine (100) of claim 1, wherein the waste management system is configured to collect and convey the removed bark away from the machine, ensuring a clean working environment and facilitating the disposal or repurposing of bark waste.
12. The debarking machine (100) of claim 1, further comprising:
an automated control system designed to adapt the debarking process to different log species, sizes, and shapes in real time, ensuring consistent bark removal with minimal damage to the underlying wood.
13. The debarking machine (100) of claim 1, wherein the machine's structure is optimized for environmental sustainability, minimizing waste generation and resource consumption during the debarking process.