轮式刚柔耦合减损玉米摘穗割台的设计与参数优化
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摘要
为解决玉米收获机械摘穗割台籽粒损失率高的问题,该文提出利用刚柔耦合原理进行割台减损的方法。通过对摘穗过程中的果穗和籽粒进行受力分析,理论计算果穗的碰撞过程,确定改变摘穗接触部件的结构和材料,以降低籽粒损失;设计了轮式刚柔耦合减损摘穗装置,对摘穗轮进行了受力分析,依据受力分析结果及尺寸边界条件确定了摘穗轮、支架及缓冲弹簧的结构尺寸;在拉茎辊转速、摘穗轮半径、柔性体厚度三因素下,进行了三因素三水平Box-Behnken响应曲面分析法的试验设计;通过试验建立了籽粒损失率与三因素的回归数学模型,确定轮式刚柔耦合摘穗机构最优参数为:拉茎辊转速700 r/min,摘穗轮半径15 mm,柔性体厚度4 mm;在籽粒含水率为21.8%、16.7%和13.4%下,进行了轮式刚柔耦合摘穗机构和板式摘穗机构的对比试验,籽粒损失率分别降低了53.4%、48.6%和47.0%。该研究为改进玉米收获机械割台提供了理论依据和设计参考。
Grain loss rate is one of the most important performance index of corn head in mechanized harvesting. Seed harvesting is the main development direction of mechanized corn harvesting. The characters of seed harvesting corn variaty increased the urgency to reduce grain loss on corn head. The paper was proposed to solve the problem of grain loss on corn head. Theoretical analysis was conducted to the snapping process. Corn ear was subjected to pull force by the snapping rolls and the pull force transferred by corn stalk. Corn kernels were divided into 2 types due to their force condition. A kernel at the bottom end of corn ear was subjected to reaction forces by stripper plates, corn cob and the adjacent kernels and shear force by the pedicel. Kernels out of contact with the stripper plates were subjected to reaction forces by the adjacent kernels, pull force and shear force by corn cob. As the impact force was related to the impact time according to the theorem of impulse, the paper analyzed collision model between corn ear and stripper plates in the snapping process. A mathematical model was obtained about the impact time and intrinsic parameters of the system. The impact time was dependent on system mass, stiffness coefficient and damping coefficient, which laid on the mechanical structure and materials of collision objects. So, the impact force would decrease as the impact time could be prolonged by reducing the stiffness coefficient and raising the damping coefficient. The quantity of shed kernels could be reduced consequently. The paper proposed a corn head with wheel type rigid-flexible coupling snapping device to reduce loss. The corn head consisted of the frame, gear-box, snapping rolls, gathering chain, wheel type rigid-flexible coupling snapping device, and chain wheels. The wheel type rigid-flexible coupling snapping device consisted of snapping wheel axle, spring seat axle, supporting axle, buffer spring, and snapping wheel frame. Force analysis was conducted on the snapping wheel. According to the force conditions and dimension boundary condition, the structure diameters of snapping wheel, snapping wheel frame, and buffer spring were confirmed. In order to obtain the optimal parameters with the minimum loss rate of wheel type rigid-flexible coupling snapping device, the optimization experiments were conducted of the factors at 3 different levels. In the optimization experiments, the snapping wheel radius was designed at 10, 15 and 20 mm respectively, the flexible body thickness was at 2, 4 and 6 mm respectively, the snapping rolls rotating speed at 700, 800 and 900 r/min respectively. The Response Surface Analysis method was used to design the experiments. The software Design-Expert 8.0.6.1 was used to analyze the data. Regression equation was induced according to the experiment and analysis above. The optimal combination of wheel type coupling snapping device was as follows: The snapping rolls rotating speed was 700 r/min, the snapping wheel radius was 15 mm, the flexible body thickness was 4 mm. Verification contrast test was conducted between corn head with wheel type rigid-flexible coupling snapping device and the one with snapping rolls and stripper plates on corns at different moisture contents. As the kernels moisture contents were 21.8%, 16.7% and 13.4%, the grain loss rate decreased 53.4%, 48.6% and 47.0% respectively. This study provides not only theoretical basis but also design reference for the improvement of corn harvester design.
Grain loss rate is one of the most important performance index of corn head in mechanized harvesting. Seed harvesting is the main development direction of mechanized corn harvesting. The characters of seed harvesting corn variaty increased the urgency to reduce grain loss on corn head. The paper was proposed to solve the problem of grain loss on corn head. Theoretical analysis was conducted to the snapping process. Corn ear was subjected to pull force by the snapping rolls and the pull force transferred by corn stalk. Corn kernels were divided into 2 types due to their force condition. A kernel at the bottom end of corn ear was subjected to reaction forces by stripper plates, corn cob and the adjacent kernels and shear force by the pedicel. Kernels out of contact with the stripper plates were subjected to reaction forces by the adjacent kernels, pull force and shear force by corn cob. As the impact force was related to the impact time according to the theorem of impulse, the paper analyzed collision model between corn ear and stripper plates in the snapping process. A mathematical model was obtained about the impact time and intrinsic parameters of the system. The impact time was dependent on system mass, stiffness coefficient and damping coefficient, which laid on the mechanical structure and materials of collision objects. So, the impact force would decrease as the impact time could be prolonged by reducing the stiffness coefficient and raising the damping coefficient. The quantity of shed kernels could be reduced consequently. The paper proposed a corn head with wheel type rigid-flexible coupling snapping device to reduce loss. The corn head consisted of the frame, gear-box, snapping rolls, gathering chain, wheel type rigid-flexible coupling snapping device, and chain wheels. The wheel type rigid-flexible coupling snapping device consisted of snapping wheel axle, spring seat axle, supporting axle, buffer spring, and snapping wheel frame. Force analysis was conducted on the snapping wheel. According to the force conditions and dimension boundary condition, the structure diameters of snapping wheel, snapping wheel frame, and buffer spring were confirmed. In order to obtain the optimal parameters with the minimum loss rate of wheel type rigid-flexible coupling snapping device, the optimization experiments were conducted of the factors at 3 different levels. In the optimization experiments, the snapping wheel radius was designed at 10, 15 and 20 mm respectively, the flexible body thickness was at 2, 4 and 6 mm respectively, the snapping rolls rotating speed at 700, 800 and 900 r/min respectively. The Response Surface Analysis method was used to design the experiments. The software Design-Expert 8.0.6.1 was used to analyze the data. Regression equation was induced according to the experiment and analysis above. The optimal combination of wheel type coupling snapping device was as follows: The snapping rolls rotating speed was 700 r/min, the snapping wheel radius was 15 mm, the flexible body thickness was 4 mm. Verification contrast test was conducted between corn head with wheel type rigid-flexible coupling snapping device and the one with snapping rolls and stripper plates on corns at different moisture contents. As the kernels moisture contents were 21.8%, 16.7% and 13.4%, the grain loss rate decreased 53.4%, 48.6% and 47.0% respectively. This study provides not only theoretical basis but also design reference for the improvement of corn harvester design.
引文
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[2]陈志.玉米全价值收获关键技术与装备[M].北京:科学出版社,2014.
[3]郭焱,占鹏,李轩复,等.中国玉米收获损失研究:基于5省5县的调查[J].玉米科学,2018,26(5):130-136.Guo Yan,Zhan Peng,Li Xuanfu,et al.Study on yield loss of maize during harvesting in China:Based on the surveys in 5counties of 5 provinces[J].Journal of Maize Sciences,2018,26(5):130-136.(in Chinese with English abstract)
[4]Yang Li,Cui Tao,Qu Zhe,et al.Development and application of mechanized maize harvesters[J].Int J Agric&Biol Eng,2016,9(3):15-28.
[5]张林,张宝石,王霞,等.玉米收获期籽粒含水量与主要农艺性状相关分析[J].东北农业大学学报,2009,40(10):9-12.Zhang Lin,Zhang Baoshi,Wang Xia,et al.Correlation analysis of agronomic characters and grain moisture in maize harvest time[J].Journal of Northeast Agricultural University,2009,40(10):9-12.(in Chinese with English abstract)
[6]李川,乔江方,谷利敏,等.影响玉米籽粒直接机械化收获质量的生物学性状分析[J].华北农学报,2015,30(6):164-169.Li Chuan,Qiao Jiangfang,Gu Limin,et al.Analysis of maize biological traits which affected corn kernel mechanically harvesting qualities[J].Acta Agricultural Boreali-Sinica,2015,30(6):164-169.(in Chinese with English abstract)
[7]张海勇,王天林,吴贵山.玉米单挡板纯拉摘穗与拉弯摘穗方法及其机构研究[J].农业机械学报,1982,13(2):66-72.Zhang Haiyong,Wang Tianlin,Wu Guishan.An investigation on the corn snapping methods of single-side shield pure stretch and stretch-bend mix on their experimental mechanisms[J].Transactions of the Chinese Society for Agricultural Machinery,1982,13(2):66-72.(in Chinese with English abstract)
[8]Petkevicius S,Steponavicius D,Puzauskas E.Grain separation from pith under quasi-static radial compression of corn ear[C]//Proceedings of 17th International Conference,Kaunas:Mechanika,2012:224-228.
[9]Li X,Du Z,Ma Y,et al.Discrete analysis of maize ear at different impact head[J].Applied Mechanics and Materials,2014(651/652/653):323-327.
[10]周海玲,李清龙,张强强,等.玉米籽粒和玉米芯间连接的理论分析与试验研究[C]//2012颗粒材料计算力学会议.张家界:CMGM,2012:477-484.Zhou Hailing,Li Qinglong,Zhang Qiangqiang,et al.Theoretical analysis and experimental research on the connection between corn kernel and corncob[C]//National Conference on Computational Mechanics of Granular Materials,Zhangjiajie:CMGM,2012:477-484.(in Chinese with English abstract)
[11]赵武云.组合式螺旋板齿种子玉米脱粒装置研究[D].杨凌:西北农林科技大学,2012.Zhao Wuyun.Research on Combined Type of Spiral Bar Tooth Threshing Mechanism for Seed Corn[D].Yangling:Northwest A&F University,2012.(in Chinese with English abstract)
[12]Singh S S,Finner M F,Rohatgi P K,et al.Structure and mechanical properties of kernels:A hybrid composite material[J].Journal of Materials Science,1991,26:274-284.
[13]Cheng Xuduo,Zhang Qiang,Yan Xiaojie,et al.Compressibility and equivalent bulk modulus of shelled corn[J].Biosystems Engineering,2015,140:91-97.
[14]张丽萍,李其昀.仿生玉米掰穗装置掰穗速度与功耗试验[J].农业工程学报,2015,31(19):9-14.Zhang Liping,Li Qiyun.Speed of bionic breaking corn ear hand and experiment on power consumption[J].Transactions of the Chinese Society of Agricultural Engineering(Transactions of the CSAE),2015,31(19):9-14.(in Chinese with English abstract)
[15]程修沛,贾晓东,陈美舟,等.上拉茎掰穗式玉米收获台架试验与分析[J].农业工程学报,2016,32(22):50-55.Cheng Xiupei,Jia Xiaodong,Chen Meizhou,et al.Experiment and analysis on test device of corn ear picking by pulling stalk upwards[J].Transactions of the Chinese Society of Agricultural Engineering(Transactions of the CSAE),2016,32(22):50-55.(in Chinese with English abstract)
[16]张智龙,张东兴,崔涛,等.玉米梳齿摘穗单体机构设计与试验[J].农业工程学报,2014,30(20):1-9.Zhang Zhilong,Zhang Dongxing,Cui Tao,et al.Design and experiment of corn stripping monomer mechanism[J].Transactions of the Chinese Society of Agricultural Engineering(Transactions of the CSAE),2014,30(20):1-9.(in Chinese with English abstract)
[17]贺俊林,佟金,胡伟,等.辊型和作业速度对玉米收获机摘穗性能的影响[J].农业机械学报,2006,37(3):46-50.He Junlin,Tong Jin,Hu Wei,et al.Influence of snapping roll type and harvesting speed on 4YW-Q corn harvester[J].Transactions of the Chinese Society for Agricultural Machinery,2006,37(3):46-50.(in Chinese with English abstract)
[18]耿爱军,杨建宁,张姬,等.玉米摘穗收获机械损伤影响因素分析[J].农业工程学报,2016,32(22):56-62.Geng Aijun,Yang Jianning,Zhang Ji,et al.Influence factor analysis of mechanical damage on corn ear picking[J].Transactions of the Chinese Society of Agricultural Engineering(Transactions of the CSAE),2016,32(22):56-62.(in Chinese with English abstract)
[19]陈美舟,孙雪峰,程修沛,等.卧辊式摘穗机构摘穗辊高度差对玉米籽粒损失的影响[J].农业工程学报,2017,33(4):63-68.Chen Meizhou,Sun Xuefeng,Cheng Xiupei,et al.Effect of height difference of horizontal corn snapping rollers device on grain loss[J].Transactions of the Chinese Society of Agricultural Engineering(Transactions of the CSAE),2017,33(4):63-68.(in Chinese with English abstract)
[20]裴建杰,范国昌.对玉米收获中籽粒破碎和损失的影响因素试验研究[J].河北农业大学学报,2012,35(1):102-105.Pei Jianjie,Fan Guochang.Experimental research of influence factor on seed damage rate and loss rate in harvester corn[J].Journal of Agricultural University of Hebei,2012,35(1):102-105.(in Chinese with English abstract)
[21]中国农业机械化科学研究院.农业机械设计手册(下册)[M].北京:中国农业科学技术出版社,2007.
[22]范国昌,王惠新,籍俊杰,等.影响玉米摘穗过程中籽粒破碎和籽粒损失率的因素分析[J].农业工程学报,2002,18(4):72-74.Fan Guochang,Wang Huixin,Ji Junjie,et al.Analysis of influence factor on seed damage rate and loss rate during picking corn-cob[J].Transactions of the Chinese Society of Agricultural Engineering(Transactions of the CSAE),2002,18(4):72-74.(in Chinese with English abstract)
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