Single-shaft soft material shredder series videoActual product photos of the single-shaft soft material shredder seriesSingle-shaft soft material shredder series parametersApplications of Single-Shaft Soft Material Shredder Series ●PE, PP, BOPP, PU, PET films, woven bags, b
Advantages of Single-Shaft Soft Material Shredder Series
Hopper structure
The single-shaft soft material shredder series features a hydraulic feeding mechanism with an integrally moving hopper. Green columns, similar to those used in injection molding machines, are added to both sides of the main shaft as guide rails. These guide rails have built-in copper bushings, lubricated with graphene for automatic oil supply. Additionally, oil can be applied to the green columns to further increase lubrication and extend the machine's lifespan.
Advantages:
a. Unrestricted feeding and controllable feed rate: The hopper movement moves the material closer to and away from the main shaft, ensuring a smooth shredding process. Material forward and backward movement is automatically controlled by a Siemens PLC, with the main shaft load determined by the current. This effectively reduces the number of reverse rotations and protects the reducer.
b. Traditional shredders use an internal pusher plate, where the material directly contacts the plate, preventing lubrication. This leads to a widening gap between the pusher plate and the guide rails, eventually causing the pusher plate to jam, requiring machine shutdown and removal of the plate before resuming operation.
c. At the same time, in the traditional structure, when there is too much feed, the material cannot be carried away from the main shaft by the push plate. If the load is too high, the machine will frequently reverse. Too many reversals will damage the gears of the gearbox and reduce its service life.
Shredder main shaft
The main shaft of our single-shaft soft material shredder series uses forged round steel as raw material, resulting in higher density and strength. The round steel undergoes tempering, forging, and rough machining to achieve a standard shape. The main shaft is precision-machined entirely in our own machining center, with tolerances controlled within 10 microns (1mm equals 100 microns).
The design of the shredder's main shaft and cutter head structure is the result of nearly ten years of practical production experience. The cutter head structure features a stepped spiral shape, ensuring more even load distribution during shredding and stable operation.
Advantages:
a. The new Bei main shaft is a single forged component. Traditional shredders use seamless steel pipes welded together, with the cutter head welded to the pipes. The welding process involves high temperatures, and the contact points experience thermal expansion and contraction. After welding, the overall shaft tolerance can reach 4-5mm. This inevitably results in a large blade gap, whereas our blade gap can be adjusted to 0.5mm. A smaller blade gap means a lower load during shredding, higher machine output, and a longer service life. Furthermore, the excessively large gap in traditional structures often leads to shaft entanglement when processing soft materials, causing frequent machine reversals and impacting the lifespan of the motor and gearbox. The service life of welded cutter discs is far shorter than our overall structure, frequently resulting in cutter discs falling and damaging the shredding chamber. Our cutter discs, however, will never fall off.
b. Regarding the main shaft cutter disc structure, traditional shredders use round steel welded cutter discs, where the entire shaft only has a concave-convex structure. While the gap between the fixed and moving blades is small, the gap between the fixed blades and the main shaft is large, frequently causing shaft entanglement when shredding soft materials. Our randomly selected grooved cutter disc ensures a 0.5mm gap between the moving and fixed blades, and the gap between the fixed blades and the main shaft can be controlled to 1mm, preventing shaft entanglement.
Shredder wall panel processing
The back baffle, left and right side panels, and hopper ears of the single-shaft soft material shredder series are all machined using a gantry milling process, ensuring overall precision control within 1mm. This results in greater machine stability and a longer service life.
Traditional shredders rely on rough welding and grinding without high-precision machining. Their operating principle is based on direct, direct contact; if the connections are not precise enough, structural vibrations will occur during later operation, severely impacting the machine's lifespan.
Shredder Gearbox
For our single-shaft soft material shredder series, we selected a high-torque, tooth-surface type gearbox from Guomao. Because we chose a domestic brand, considering that domestic material standards and processing techniques do not meet German standards, we opted for a larger-scale selection. The international standard service factor for gearboxes is 2.2, while Xinbei's gearboxes have a service factor of 5. Simply put, our gearboxes are several sizes larger than those from domestic factories. Our gearboxes are all equipped with a water-cooling system to maximize their service life.
The connection between the gearbox and the main shaft is a coupling. This tight-fitting coupling effectively mitigates the backlash generated by the main shaft during shredding, protecting the gearbox gears. Furthermore, the coupling uses a through-pin structure, where most of the backlash is absorbed by the through-pin. Later, only the through-pin needs to be replaced, significantly reducing operating costs. Traditional shredders use a sleeve shaft design, where the shredder's main shaft is directly fitted into the gearbox. This loose fit causes the gearbox to wobble during shredding, and the recoil force of the main shaft acts directly on the gearbox's gears, resulting in a very short lifespan for the gearbox.
Shredder bearings
The bearing housings of our single-shaft soft material shredder series are machined as a single unit in a machining center, with a center height tolerance of less than 10 microns between the bearing housing and the main shaft, significantly improving installation accuracy. Because the main shaft is a solid, integral structure with high load capacity, we have chosen an enlarged bearing design, making the bearing twice the size of those in traditional shredders.
The shredder bearings are installed using a gentle heat treatment process, requiring strict adherence to specifications. Traditional factories, for ease of installation, often use direct heating, which heats the bearing's inner bore and easily damages it.
Safety Protection
Our single-shaft soft material shredder series prioritizes safety in its design. For hard materials, all machines are equipped with vertical safety hoppers and safety covers. Furthermore, for ease of operation and maintenance, the machines are equipped with a complete set of stairs, handrails, and a safety maintenance platform, reducing potential safety hazards for users.
Traditional shredders, limited by their machine structure (moving pusher plate, smaller frame), often use simple flared hoppers to save costs, resulting in low safety and significant risks.
Electrical Control System
The electrical control components of the single-shaft soft material shredder series are mostly from Siemens and Schneider Electric, ensuring stable and reliable quality. The machine's operating system uses a Siemens PLC system, which effectively controls the forward and backward movement of the hopper, and features comprehensive overload and high-temperature protection systems. The control panel is a Siemens text display; after machine debugging, the operator only needs to control F1 to start and F2 to stop. The system will automatically and stably operate throughout the entire process, effectively managing the current based on the amount of material input and the moving hopper. This results in higher automation, greater machine stability, and a longer service life.
Traditional shredders rely on simple button controls and cannot effectively coordinate the load inside the hopper based on current, leading to frequent reverse rotations and significantly limiting machine stability and lifespan.
Overall Machine Structure
The single-shaft soft material shredder series features a rigid, integrated structure. Taking these factors into consideration, during manufacturing, the frame and plate thickness were optimized, resulting in a machine weight nearly 1.5 times heavier than traditional machines. It can achieve long-term operation.
Hydraulic System
The single-shaft soft material shredder series uses a high-strength hydraulic system. The oil pump is a large-diameter, multi-length pump, the hydraulic station has a higher capacity, and the hydraulic hoses are high-pressure hoses used on forklifts. During machine operation, the hydraulic load is neutral; simply put, we use a larger and stronger hydraulic system to ensure the hydraulic system operates under low load. The hydraulic system is also equipped with water cooling to ensure stable and long-term operation.
Traditional shredder hydraulic systems are very small, only using pressure structures sufficient to push the pusher plate. Our smallest hydraulic system can achieve a thrust of 10T, while traditional shredders only have 3T.
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