Design and Testing of Key Components for a Multi-Stage Crushing Device for High-Moisture Corn Ears Based on the Discrete Element Method

Abstract

To improve the crushing efficiency and crushing pass rate of high-moisture corn ears (HMCEs), a multi-stage crushing scheme is proposed in this paper. A two-stage crushing device for HMCEs is designed, and the ear crushing process is analyzed. Firstly, a simulation model for HMCEs was established in EDEM software (2018), and the accuracy of the model was verified by the shear test. Subsequently, single-factor simulation experiments were conducted, with the crushing rate serving as the evaluation index. The optimal working parameter ranges for the HMCE device were identified as a primary crushing roller speed of 1200–1600 revolutions per minute (r/min), a secondary crushing roller clearance of 1.5–2.5 mm, and a secondary crushing roller speed of 2750–3750 r/min. A Box–Behnken experiment was conducted to establish a multiple regression equation. With the objective of maximizing the qualified crushing pass rate, the optimal combination of parameters was revealed: a primary crushing roller speed of 1500 r/min, a secondary crushing roller clearance of 2.5 mm, and a secondary crushing roller speed of 3280 r/min. The pass rate of corn cob crushing in the simulation test was 98.2%. The physical tests, using the optimized parameter combination, yielded a qualified crushing rate of 97.5%, which deviates by 0.7% from the simulation results, satisfying the requirement of a qualified crushing rate exceeding 95%. The experimental outcomes validate the rationality of the proposed crushing scheme and the accuracy of the model, providing a theoretical foundation for subsequent research endeavors.