稻麦联合收获开沟埋草多功能一体机的设计
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摘要
针对目前我国抢收抢种季节因农村劳动力结构性不足而出现的许多地方焚烧秸秆造成资源浪费、环境污染等,以及我国稻麦两熟地区墒沟埋草法存在机器两次作业和人工埋草的缺点,本研究本着农机与农艺相结合的原则,以稻麦联合收割机及开沟机为研究对象,以开发一次作业即可完成稻麦收获、墒沟开挖、秸秆入沟还田等工序的新型多功能一体机(稻麦联合收获开沟埋草多功能一体机,简称多功能一体机)为目的,在以下几个方面进行了研究：
1.墒沟埋草式秸秆还田法成功实施的前提是开挖出适合埋(集)草的墒沟,而开沟质量、侧向抛土均匀性(田间平整度)等与开沟装置结构参数、作业参数密切相关；在开沟装置刀盘提升高度(刀盘及其支架等结构参数)满足多功能一体机安全下地作业的前提下,材料最省、成本最低是现代设计方法追求的目标。因此,本文以刀盘提升高度最大、刀盘升降装置结构尺寸最小及油缸行程最短为目标函数建立开沟装置参数优化设计数学模型,并运用Matlab优化工具箱对其进行计算,经圆整优化结果后,得刀盘升降装置最小结构尺寸、油缸最大行程及刀盘最大提升高度分别为885mm、182mm和850mm。
2.为充分发挥开沟装置各级链传动的传动能力,减小传动链轮组的体积、重量,并使传动平稳、轻便、灵活,以实际工作条件下各级链条所能传递的功率[P]与计算功率Pj充分接近为目标函数建立优化设计数学模型,对链轮减速系传动比进行优化分配,得第一、二级链传动的传动比分别为1.78和1.42。
3.多功能一体机的作业效率、作业质量很大程度上取决于整机动力是否配套、收获与开沟部件是否速度同步。针对上述问题,对收获、开沟及行走等装置功率消耗进行了研究,并在部件试验的基础上,建立了整机功率配套数学模型,为同类型机具开发奠定了功率配套基础。
4.为了减少传统设计方法中样机多次加工成本、试验费用及缩短样机开发周期,并增加零部件的直观性,运用Pro/E软件对开沟装置及其传动部件建立了三维参数化模型,并进行了虚拟装配,同时运用仿真软件ADAMS对反转开沟作业进行了运动仿真,仿真结果验证了开沟部件的运动分析的正确性。
5.根据各设计结果,加工了开沟装置及其传动系统零部件,并完成了整机装配。田间试验表明,在成熟稻麦联合收割机上加装开沟装置,并采用反转方式作业,沟内回土较少,开沟装置工作可靠、开沟质量稳定,梯形沟不仅利于秸秆入沟,墒沟边坡也不易塌陷,满足农艺上埋草、排水要求。机器各装置因获得合适的动力而保持速度同步,其作业效率、沟形参数(可调)等指标满足设计要求；当配套动力不变时(46kW)时,与原联合收割机相比,样机收获效率有所降低,但由于该机一次作业即可完成作物收获、墒沟开挖及秸秆入沟处理,因此其综合效率较高。
In solving the problem of straw burning practices, a consequence from labor shortage during the harvesting and sowing season in rural regions, and which results into the waste of energy resources and a potential pollution to the environment, a combined harvester was designed by combining the functions of the cereal crop combine harvester and the ditches. The main purpose of the machine was to facilitate ditching and stalk-disposing while performing harvesting, so that the two-pass field operation of harvesting and ditching and stalk-disposing was avoided. The main achievements include:
The prerequisite for ditching and stalk-disposing was the proper ditching. While the quality and the uniformity of the ditching operation was related to the structure and operational parameters of the ditcher. If the disc adjustment height satisfies the operational demand of the multi-function harvester, the objective of the machine design turns out to be the minimum material used and the lowest cost of the production. Therefore the objective function of this work was designed as the maximum adjustment height of the disc, the minimum disc size and the least displacement of the hydraulic cylinder. These resulted into a optimization function for the ditcher, which, was further calculated in Matlab to yield the sizes for the minimum disc size, the maximum displacement of the hydraulic cylinder and the maximum adjustment height of the disc to be885mm,182mm and850mm, respectively.
To fully exploit the power transmission of each level and to reduce the size and the mass of the chain system for a stable, simple and flexible working condition, a optimization model was proposed by extensively approximating the transmitted power [P] by each level to the calculated power Pj. This optimization determined the power transmission ratioes for the first and the second level to be1.78and1.42.
The operational efficiency and the quality of the multi-function harvester was mainly influenced by the condition of whether the power system was compatible and if the harvesting and the ditching assembles were synchronous. Thus the power consumption of the harvesting and the ditching parts were studied and based on which a mathematical model of the overall power demand by the machine was provided, which could be applied on all similar models.
With an aim of reducing the cost of machine production and experiment and to reduce the development cycle of the model machine, as well as the improvement of the visibility, the Pro/E development software was used to generated the3-D models of the ditching and power transmission mechanisms. The developed model was further simulated in the ADAMS to test the correctness of the movement of the ditching parts.
On the basis of the design, the parts of the ditching and its power transmission assemblies were produced and assembled. Field test on the machine revealed that, by attaching the ditching parts on the harvester and moving in a reversible direction, very little soil was observed falling back into the trapezoid ditch. The generated ditch allowed the stalk to be collected in and the field well drained. As each part of the machine were well synchronized, the overall working efficiency and the ditching parameters were proved to be satisfactory. If no modification was made on the power (46kW) the revised harvester gave a lower harvesting efficiency, but a higher composite working efficiency when the once-over field operation was considered as compared with the stepped field work of harvesting and the ditching for stalk-disposing.
1.墒沟埋草式秸秆还田法成功实施的前提是开挖出适合埋(集)草的墒沟,而开沟质量、侧向抛土均匀性(田间平整度)等与开沟装置结构参数、作业参数密切相关；在开沟装置刀盘提升高度(刀盘及其支架等结构参数)满足多功能一体机安全下地作业的前提下,材料最省、成本最低是现代设计方法追求的目标。因此,本文以刀盘提升高度最大、刀盘升降装置结构尺寸最小及油缸行程最短为目标函数建立开沟装置参数优化设计数学模型,并运用Matlab优化工具箱对其进行计算,经圆整优化结果后,得刀盘升降装置最小结构尺寸、油缸最大行程及刀盘最大提升高度分别为885mm、182mm和850mm。
2.为充分发挥开沟装置各级链传动的传动能力,减小传动链轮组的体积、重量,并使传动平稳、轻便、灵活,以实际工作条件下各级链条所能传递的功率[P]与计算功率Pj充分接近为目标函数建立优化设计数学模型,对链轮减速系传动比进行优化分配,得第一、二级链传动的传动比分别为1.78和1.42。
3.多功能一体机的作业效率、作业质量很大程度上取决于整机动力是否配套、收获与开沟部件是否速度同步。针对上述问题,对收获、开沟及行走等装置功率消耗进行了研究,并在部件试验的基础上,建立了整机功率配套数学模型,为同类型机具开发奠定了功率配套基础。
4.为了减少传统设计方法中样机多次加工成本、试验费用及缩短样机开发周期,并增加零部件的直观性,运用Pro/E软件对开沟装置及其传动部件建立了三维参数化模型,并进行了虚拟装配,同时运用仿真软件ADAMS对反转开沟作业进行了运动仿真,仿真结果验证了开沟部件的运动分析的正确性。
5.根据各设计结果,加工了开沟装置及其传动系统零部件,并完成了整机装配。田间试验表明,在成熟稻麦联合收割机上加装开沟装置,并采用反转方式作业,沟内回土较少,开沟装置工作可靠、开沟质量稳定,梯形沟不仅利于秸秆入沟,墒沟边坡也不易塌陷,满足农艺上埋草、排水要求。机器各装置因获得合适的动力而保持速度同步,其作业效率、沟形参数(可调)等指标满足设计要求；当配套动力不变时(46kW)时,与原联合收割机相比,样机收获效率有所降低,但由于该机一次作业即可完成作物收获、墒沟开挖及秸秆入沟处理,因此其综合效率较高。
In solving the problem of straw burning practices, a consequence from labor shortage during the harvesting and sowing season in rural regions, and which results into the waste of energy resources and a potential pollution to the environment, a combined harvester was designed by combining the functions of the cereal crop combine harvester and the ditches. The main purpose of the machine was to facilitate ditching and stalk-disposing while performing harvesting, so that the two-pass field operation of harvesting and ditching and stalk-disposing was avoided. The main achievements include:
The prerequisite for ditching and stalk-disposing was the proper ditching. While the quality and the uniformity of the ditching operation was related to the structure and operational parameters of the ditcher. If the disc adjustment height satisfies the operational demand of the multi-function harvester, the objective of the machine design turns out to be the minimum material used and the lowest cost of the production. Therefore the objective function of this work was designed as the maximum adjustment height of the disc, the minimum disc size and the least displacement of the hydraulic cylinder. These resulted into a optimization function for the ditcher, which, was further calculated in Matlab to yield the sizes for the minimum disc size, the maximum displacement of the hydraulic cylinder and the maximum adjustment height of the disc to be885mm,182mm and850mm, respectively.
To fully exploit the power transmission of each level and to reduce the size and the mass of the chain system for a stable, simple and flexible working condition, a optimization model was proposed by extensively approximating the transmitted power [P] by each level to the calculated power Pj. This optimization determined the power transmission ratioes for the first and the second level to be1.78and1.42.
The operational efficiency and the quality of the multi-function harvester was mainly influenced by the condition of whether the power system was compatible and if the harvesting and the ditching assembles were synchronous. Thus the power consumption of the harvesting and the ditching parts were studied and based on which a mathematical model of the overall power demand by the machine was provided, which could be applied on all similar models.
With an aim of reducing the cost of machine production and experiment and to reduce the development cycle of the model machine, as well as the improvement of the visibility, the Pro/E development software was used to generated the3-D models of the ditching and power transmission mechanisms. The developed model was further simulated in the ADAMS to test the correctness of the movement of the ditching parts.
On the basis of the design, the parts of the ditching and its power transmission assemblies were produced and assembled. Field test on the machine revealed that, by attaching the ditching parts on the harvester and moving in a reversible direction, very little soil was observed falling back into the trapezoid ditch. The generated ditch allowed the stalk to be collected in and the field well drained. As each part of the machine were well synchronized, the overall working efficiency and the ditching parameters were proved to be satisfactory. If no modification was made on the power (46kW) the revised harvester gave a lower harvesting efficiency, but a higher composite working efficiency when the once-over field operation was considered as compared with the stepped field work of harvesting and the ditching for stalk-disposing.
引文
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