风筛式清选装置理论及试验研究
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摘要
清选装置是联合收获机的重要组成部分,它的性能优劣直接影响到整机的工作性能。农业物料清选过程是气固两相流场、农业物料群自身特性和振动筛面的综合效应。开展风筛式清选装置的研究,分析清选室内气流场的分布规律,探索农业物料在筛面上的运动规律,不仅能为现有清选装置的设计、优化提供依据,还能为寻找新的筛分方法提供启发,具有重要的现实意义和科学研究价值。本文在这样的背景下,结合国家自然科学基金和“863”计划等项目,综合运用计算流体力学、散体动力学和气固两相流等理论着重开展了风筛式清选装置理论及试验研究,主要工作包括：
1、对水稻清选混合物成分进行了分析,混合物中的主要成分有籽粒、轻杂余、短茎秆和长草,在混合物中影响清选性能的主要是短茎秆和轻杂余。实验测量了水稻籽粒的三维几何尺寸、形状特征以及密度、摩擦系数和恢复系数等力学参数,建立了三维模型。利用自行研制的DFPF-25型物料悬浮速度测定装置,对清选混合物中的主要成分进行了测定,试验结果表明带籽粒的小枝梗的悬浮速度接近于饱满籽粒的悬浮速度,短茎秆的悬浮速度分布范围与籽粒的悬浮速度分布范围存在着重叠部分,采用气流清选将重叠部分的籽粒和短茎秆分离困难。所得数据为后面的数值模拟和台架试验提供了依据。
2、依据风筛式清选装置的结构特征建立了全流道三维模型,应用计算流体力学(CFD)的理论与方法,进行网格划分,基于Reynolds时均化的连续方程、Navier-Stokes方程和标准的k-ε湍流模型构成封闭方程组,对不同的风机出风口角度、风机出风口风速和筛面中部与清选室顶部距离三个参数进行了气流场数值模拟,分析了这三个参数对清选室气流场的影响,并进行了试验验证。结果表明：风机出风口角度和筛面中部与清选室顶部距离对清选室气流场的影响较大,风机出风口风速只影响到气流速度而对气流场的分布规律影响不大,模拟结果与试验测量结果总体趋势基本吻合,这表明了利用Fluent进行数值模拟的正确性,可为研究风筛式清选装置清选室内的气流场提供一种新方法。
3、基于离散元法(DEM)建立了籽粒与籽粒、籽粒与壁面之间的接触碰撞模型,利用颗粒离散元软件(EDEM)对物料单颗粒和物料群进行数值模拟,结果表明：抛掷指数是影响颗粒运动的决定因素,模拟结果和理论分析具有一致性；在其他条件一定的情况下,随着振幅和频率的增加,物料沿筛面后移的速度增加,同时透筛效率高,但振幅和频率的增加也会造成损失的增加；随着振动方向角的增大,在25°到45°范围内,物料沿筛面后移的速度增加,在45°时达到最大,超过45°之后,随着振动方向角的增加,物料沿筛面后移的速度降低,振动方向角较小时,抛掷指数低,物料不能被抛起,物料分层效果较差,使籽粒的透筛效率低,但随着振动方向角的过大,抛掷指数加大,物料与筛面接触时间减少,也会降低透筛效率,在振动方向角为35°时透筛效率最高,清选损失几乎为零；从模拟效果的综合分析可以得出：在没有风力因素的影响下,筛面倾角为4°、振幅为30mm、频率为5Hz、振动方向角为35°时,清选效果最佳,与试验结果基本一致,此时的抛掷指数为1.56。
4、应用CFD-DEM耦合技术,采用Hertz-Mindlin接触模型模拟颗粒间以及颗粒与筛面间的碰撞,选用考虑相间耦合作用的Eulerian模型,描述了风筛式清选装置中颗粒在筛面上的运动,得出：①由于短茎秆的密度较小,风机出风口风速角对其在筛面上的纵向运动速度影响较大,籽粒密度较大,其所受影响较小；风速对籽粒和短茎秆的垂直速度的影响很小；随着风速的增加,物料的后移加快,有利于提高风筛式清选装置的处理能力,但是会增加籽粒损失。②籽粒主要分布在距筛面前端97.5mm～390mm之间,随着风机出风口风速的增加,籽粒在筛下的分布后移,在距筛面前端487.5mm之后籽粒数量很少,因此,如果物料中杂余较少可以缩短筛面长度。③通过试验验证,模拟结果和试验结果基本一致,因此利用CFD-DEM耦合仿真对风筛式清选装置进行数值模拟是可行的,利用数值仿真可以为风筛式清选装置的改进设计提供依据。
5、以离心风机倾角、离心风机转速、振动筛振幅和振动筛频率为四个因素,分别取四个水平建立正交试验表L16(44),按照试验表在清选试验台上进行正交试验。对试验结果进行方差分析,结果表明：离心风机转速、振动筛振幅及振动筛频率对清洁率都有极显著的影响,离心风机倾角对清洁率有显著影响；离心风机转速对损失率有极显著的影响,振动筛振幅对损失率有显著的影响,振动筛频率和离心风机倾角对损失率的影响不显著；影响清洁率和损失率的因素主次顺序是：离心风机转速\振动筛振幅\振动筛频率\离心风机倾角。
6、利用DPS数据处理系统进行回归分析,根据试验数据分别建立清洁率Y、损失率S与离心风机倾角x1、离心风机转速x2、振动筛振幅x3、振动筛频率x4之间的回归方程数学模型；在此基础上,利用多目标遗传算法对风筛式清选系统进行工作参数优化,得到最佳的解集,经试验验证优化的结果是可靠的,为决策者在设计风筛式清选装置时提供科学依据,以达到兼顾清洁率和损失率两方面的要求。
As an important part of the combine harvester, Cleaning unit's performance directly affects the whole machine characteristic. Agricultural materials cleaning process is the combined effect of gas-solid two-phase flow field, their own characteristics of agricultural materials group and vibration screen surface. There are many factors affecting the cleaning performance. It is of great significance to study air-and-screen cleaning device, to analyze air flow distribution of cleaning shoe, to explore the motion law of agricultural materials on the screen surface, which will not only provide theoretical basis for the design and optimization of the existing typical cleaning unit, but also give theoretical inspiration to looking for a new way of the cleaning. Therefore, in this paper, computational fluid dynamics, discrete particle dynamics and gas-solid two-phase flow theory were comprehensively applied to study on working mechanism of air-and-screen cleaning unit. The major research work is as follows:
Composition of rice cleaning mixture was analyzed. The threshing mixture consists of grain, light impurities, short stems and long grass. The main compositions influencing the performance were short stems and light impurities. Three-dimension geometry size, shape characteristics and mechanical parameters of the rice grain such as density, friction coefficient and recovery coefficient were measured; as a result, a 3-D rice grain model was established. Suspended speed of the main components of the mixture was measured by using self-made DFPF-25 materials suspended speed measuring device. Suspended speed of small branch with grain closes to full grain suspended speed. The range of suspended speeds of short stem overlaps with that of grain. To separate overlapping parts of the grain and short stem by air cleaning is difficult. These data provide the basis for the bench test and numerical simulation.
The three dimensional models of the whole flow was established according to the mechanism of the air-and-screen cleaning unit. In order to study the distribution of air flow field in air-and-screen cleaning device, meshing was completed by using the Computational Fluid Dynamics (CFD) theory and method, Reynolds continual equation, N-S equations and standard k-εturbulence model were applied to form closed equations. The air flow field simulation was carried out on the conditions of different fan outlet angles, different fan outlet speeds and different distances from top to surface of the screen. The three parameters' effects on the air flow field were analyzed and the experimental verification was carried out. The results show that angle of fan outlet and distances from top to surface of screen have greater effect on air flow field in air-and-screen cleaning device. Air speed at fan outlet has less effect on air flow field. And a good agreement was found between measured value and simulated value. This demonstrates that numerical simulation of air flow field in air-and-screen cleaning mechanism using CFD software Fluent is correct. And this provides a new method for studying on air-and-screen cleaning unit.
Contact-impact models of grain-grain and grain-wall were established based on distinct element method (DEM). Numerical simulations of the single particle and material group were carried out using particle discrete element software (EDEM). The results show that throwing index is determinant factor affecting particle motion. Simulation results and theoretical analysis are consistent. As other conditions kept unchanged, with the amplitude and frequency increased, the longitudinal moving speed of the material and efficiency of the material passing the screen increased, and cleaning loss increased as well. At 25°to 45°range, with vibration direction angle increased, longitudinal moving speed of the material increased, the highest velocity occurred at 45°; when the angle was more than 45°, longitudinal moving speed of the material gradually decreased; efficiency of the material passing the screen was highest at 35°and the cleaning loss was almost 0. Based on comprehensive analysis of simulation, results can be drawn that without wind factor at the condition that screen surface dip of 4°, amplitude of 30mm, frequency of 5Hz, vibrating direction angle of 35°, the cleaning result is best, in which case throwing index was 1.56.
Using CFD-DEM coupling technique, the grain-grain and grain-wall impact was simulated in a Hertz-Mindlin model, the movement particles moving on the screen of the air-and-screen cleaning device was described by using Eulerian model which considers coupling impact. Simulation results showed that:(a)Due to the small density of short stem, the fan outlet speed influenced the stem's longitudinal moving speed on the screen more, while the density was big enough, the influence was much less; the fan outlet speed influenced the vertical velocity slightly; as speed increased, the faster move of materials enhance the processing capacity of the air-screen cleaning device, however, the grain loss increased. (b)The grain distributed mainly in the range of 97.5-390mm to the front of the screen, as the fan outlet speed increased, the distribution of the grain moved back and there are few grain more than 487.5 mm to the screen. As a result, the screen could be shortened if there were few impurities in materials. (c) Comparison of numerical simulation results with experiments has demonstrated adequate agreement. It showed that numerical simulation of material motion on vibrating screen of air-and-screen cleaning device based on CFD-DEM is feasible. The results provide a basis for improving the design on air-and-screen cleaning device of combine
Orthogonal design (L6(44)) of four factors was established, including angle of centrifugal fan, centrifugal fan speed, vibration screen amplitude and frequency of vibrating screen, four levels of every factor. Arranged the tests based on the orthogonal test table, improved clean rate of the grains and reducing loss rate were regarded as detecting index, the optimum method of air-and-screen cleaning unit was assessed. As test results for variance analysis, results indicate that:within test range, centrifugal fan speed, vibration screen amplitude and frequency of vibrating screen had significant greatly effect on clean rate, angle of centrifugal fan evident effect on clean rate; centrifugal fan speed had significant greatly effect on loss rate, vibration screen amplitude had significant greatly effect on loss rate, but angle of centrifugal and fan frequency of vibrating screen had no significant effect on loss rate; effect clean rate and loss rate of factors primary and secondary order is:centrifugal fan speed\vibrating screen amplitude\frequency of vibrating screen\angle of centrifugal fan.
By means of regression analysis, applying DPS software, mathematical models of clean rate Y, losing rate S, centrifugal fan angle x1, centrifugal rotating speed x2, vibration screen amplitude x3 and vibration screen frequency x4 were established. We applied multi-objective optimization based on the genetic algorithm. The Pareto optimal solution was obtained and verified. The results provided reference basis for practical design and utilization of the air-and screen cleaning unit, so as to give consideration to both clean rate and loss rate.
1、对水稻清选混合物成分进行了分析,混合物中的主要成分有籽粒、轻杂余、短茎秆和长草,在混合物中影响清选性能的主要是短茎秆和轻杂余。实验测量了水稻籽粒的三维几何尺寸、形状特征以及密度、摩擦系数和恢复系数等力学参数,建立了三维模型。利用自行研制的DFPF-25型物料悬浮速度测定装置,对清选混合物中的主要成分进行了测定,试验结果表明带籽粒的小枝梗的悬浮速度接近于饱满籽粒的悬浮速度,短茎秆的悬浮速度分布范围与籽粒的悬浮速度分布范围存在着重叠部分,采用气流清选将重叠部分的籽粒和短茎秆分离困难。所得数据为后面的数值模拟和台架试验提供了依据。
2、依据风筛式清选装置的结构特征建立了全流道三维模型,应用计算流体力学(CFD)的理论与方法,进行网格划分,基于Reynolds时均化的连续方程、Navier-Stokes方程和标准的k-ε湍流模型构成封闭方程组,对不同的风机出风口角度、风机出风口风速和筛面中部与清选室顶部距离三个参数进行了气流场数值模拟,分析了这三个参数对清选室气流场的影响,并进行了试验验证。结果表明：风机出风口角度和筛面中部与清选室顶部距离对清选室气流场的影响较大,风机出风口风速只影响到气流速度而对气流场的分布规律影响不大,模拟结果与试验测量结果总体趋势基本吻合,这表明了利用Fluent进行数值模拟的正确性,可为研究风筛式清选装置清选室内的气流场提供一种新方法。
3、基于离散元法(DEM)建立了籽粒与籽粒、籽粒与壁面之间的接触碰撞模型,利用颗粒离散元软件(EDEM)对物料单颗粒和物料群进行数值模拟,结果表明：抛掷指数是影响颗粒运动的决定因素,模拟结果和理论分析具有一致性；在其他条件一定的情况下,随着振幅和频率的增加,物料沿筛面后移的速度增加,同时透筛效率高,但振幅和频率的增加也会造成损失的增加；随着振动方向角的增大,在25°到45°范围内,物料沿筛面后移的速度增加,在45°时达到最大,超过45°之后,随着振动方向角的增加,物料沿筛面后移的速度降低,振动方向角较小时,抛掷指数低,物料不能被抛起,物料分层效果较差,使籽粒的透筛效率低,但随着振动方向角的过大,抛掷指数加大,物料与筛面接触时间减少,也会降低透筛效率,在振动方向角为35°时透筛效率最高,清选损失几乎为零；从模拟效果的综合分析可以得出：在没有风力因素的影响下,筛面倾角为4°、振幅为30mm、频率为5Hz、振动方向角为35°时,清选效果最佳,与试验结果基本一致,此时的抛掷指数为1.56。
4、应用CFD-DEM耦合技术,采用Hertz-Mindlin接触模型模拟颗粒间以及颗粒与筛面间的碰撞,选用考虑相间耦合作用的Eulerian模型,描述了风筛式清选装置中颗粒在筛面上的运动,得出：①由于短茎秆的密度较小,风机出风口风速角对其在筛面上的纵向运动速度影响较大,籽粒密度较大,其所受影响较小；风速对籽粒和短茎秆的垂直速度的影响很小；随着风速的增加,物料的后移加快,有利于提高风筛式清选装置的处理能力,但是会增加籽粒损失。②籽粒主要分布在距筛面前端97.5mm～390mm之间,随着风机出风口风速的增加,籽粒在筛下的分布后移,在距筛面前端487.5mm之后籽粒数量很少,因此,如果物料中杂余较少可以缩短筛面长度。③通过试验验证,模拟结果和试验结果基本一致,因此利用CFD-DEM耦合仿真对风筛式清选装置进行数值模拟是可行的,利用数值仿真可以为风筛式清选装置的改进设计提供依据。
5、以离心风机倾角、离心风机转速、振动筛振幅和振动筛频率为四个因素,分别取四个水平建立正交试验表L16(44),按照试验表在清选试验台上进行正交试验。对试验结果进行方差分析,结果表明：离心风机转速、振动筛振幅及振动筛频率对清洁率都有极显著的影响,离心风机倾角对清洁率有显著影响；离心风机转速对损失率有极显著的影响,振动筛振幅对损失率有显著的影响,振动筛频率和离心风机倾角对损失率的影响不显著；影响清洁率和损失率的因素主次顺序是：离心风机转速\振动筛振幅\振动筛频率\离心风机倾角。
6、利用DPS数据处理系统进行回归分析,根据试验数据分别建立清洁率Y、损失率S与离心风机倾角x1、离心风机转速x2、振动筛振幅x3、振动筛频率x4之间的回归方程数学模型；在此基础上,利用多目标遗传算法对风筛式清选系统进行工作参数优化,得到最佳的解集,经试验验证优化的结果是可靠的,为决策者在设计风筛式清选装置时提供科学依据,以达到兼顾清洁率和损失率两方面的要求。
As an important part of the combine harvester, Cleaning unit's performance directly affects the whole machine characteristic. Agricultural materials cleaning process is the combined effect of gas-solid two-phase flow field, their own characteristics of agricultural materials group and vibration screen surface. There are many factors affecting the cleaning performance. It is of great significance to study air-and-screen cleaning device, to analyze air flow distribution of cleaning shoe, to explore the motion law of agricultural materials on the screen surface, which will not only provide theoretical basis for the design and optimization of the existing typical cleaning unit, but also give theoretical inspiration to looking for a new way of the cleaning. Therefore, in this paper, computational fluid dynamics, discrete particle dynamics and gas-solid two-phase flow theory were comprehensively applied to study on working mechanism of air-and-screen cleaning unit. The major research work is as follows:
Composition of rice cleaning mixture was analyzed. The threshing mixture consists of grain, light impurities, short stems and long grass. The main compositions influencing the performance were short stems and light impurities. Three-dimension geometry size, shape characteristics and mechanical parameters of the rice grain such as density, friction coefficient and recovery coefficient were measured; as a result, a 3-D rice grain model was established. Suspended speed of the main components of the mixture was measured by using self-made DFPF-25 materials suspended speed measuring device. Suspended speed of small branch with grain closes to full grain suspended speed. The range of suspended speeds of short stem overlaps with that of grain. To separate overlapping parts of the grain and short stem by air cleaning is difficult. These data provide the basis for the bench test and numerical simulation.
The three dimensional models of the whole flow was established according to the mechanism of the air-and-screen cleaning unit. In order to study the distribution of air flow field in air-and-screen cleaning device, meshing was completed by using the Computational Fluid Dynamics (CFD) theory and method, Reynolds continual equation, N-S equations and standard k-εturbulence model were applied to form closed equations. The air flow field simulation was carried out on the conditions of different fan outlet angles, different fan outlet speeds and different distances from top to surface of the screen. The three parameters' effects on the air flow field were analyzed and the experimental verification was carried out. The results show that angle of fan outlet and distances from top to surface of screen have greater effect on air flow field in air-and-screen cleaning device. Air speed at fan outlet has less effect on air flow field. And a good agreement was found between measured value and simulated value. This demonstrates that numerical simulation of air flow field in air-and-screen cleaning mechanism using CFD software Fluent is correct. And this provides a new method for studying on air-and-screen cleaning unit.
Contact-impact models of grain-grain and grain-wall were established based on distinct element method (DEM). Numerical simulations of the single particle and material group were carried out using particle discrete element software (EDEM). The results show that throwing index is determinant factor affecting particle motion. Simulation results and theoretical analysis are consistent. As other conditions kept unchanged, with the amplitude and frequency increased, the longitudinal moving speed of the material and efficiency of the material passing the screen increased, and cleaning loss increased as well. At 25°to 45°range, with vibration direction angle increased, longitudinal moving speed of the material increased, the highest velocity occurred at 45°; when the angle was more than 45°, longitudinal moving speed of the material gradually decreased; efficiency of the material passing the screen was highest at 35°and the cleaning loss was almost 0. Based on comprehensive analysis of simulation, results can be drawn that without wind factor at the condition that screen surface dip of 4°, amplitude of 30mm, frequency of 5Hz, vibrating direction angle of 35°, the cleaning result is best, in which case throwing index was 1.56.
Using CFD-DEM coupling technique, the grain-grain and grain-wall impact was simulated in a Hertz-Mindlin model, the movement particles moving on the screen of the air-and-screen cleaning device was described by using Eulerian model which considers coupling impact. Simulation results showed that:(a)Due to the small density of short stem, the fan outlet speed influenced the stem's longitudinal moving speed on the screen more, while the density was big enough, the influence was much less; the fan outlet speed influenced the vertical velocity slightly; as speed increased, the faster move of materials enhance the processing capacity of the air-screen cleaning device, however, the grain loss increased. (b)The grain distributed mainly in the range of 97.5-390mm to the front of the screen, as the fan outlet speed increased, the distribution of the grain moved back and there are few grain more than 487.5 mm to the screen. As a result, the screen could be shortened if there were few impurities in materials. (c) Comparison of numerical simulation results with experiments has demonstrated adequate agreement. It showed that numerical simulation of material motion on vibrating screen of air-and-screen cleaning device based on CFD-DEM is feasible. The results provide a basis for improving the design on air-and-screen cleaning device of combine
Orthogonal design (L6(44)) of four factors was established, including angle of centrifugal fan, centrifugal fan speed, vibration screen amplitude and frequency of vibrating screen, four levels of every factor. Arranged the tests based on the orthogonal test table, improved clean rate of the grains and reducing loss rate were regarded as detecting index, the optimum method of air-and-screen cleaning unit was assessed. As test results for variance analysis, results indicate that:within test range, centrifugal fan speed, vibration screen amplitude and frequency of vibrating screen had significant greatly effect on clean rate, angle of centrifugal fan evident effect on clean rate; centrifugal fan speed had significant greatly effect on loss rate, vibration screen amplitude had significant greatly effect on loss rate, but angle of centrifugal and fan frequency of vibrating screen had no significant effect on loss rate; effect clean rate and loss rate of factors primary and secondary order is:centrifugal fan speed\vibrating screen amplitude\frequency of vibrating screen\angle of centrifugal fan.
By means of regression analysis, applying DPS software, mathematical models of clean rate Y, losing rate S, centrifugal fan angle x1, centrifugal rotating speed x2, vibration screen amplitude x3 and vibration screen frequency x4 were established. We applied multi-objective optimization based on the genetic algorithm. The Pareto optimal solution was obtained and verified. The results provided reference basis for practical design and utilization of the air-and screen cleaning unit, so as to give consideration to both clean rate and loss rate.
引文
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