水稻种绳捻制机研制及其试验研究
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摘要
水稻直播种植技术在我国水稻种植技术中占有重要的地位，具有成本低、收益高、工艺环节少、节约水资源、节省劳动力等优点。水稻纸载体绳播种植技术（简称水稻种绳直播技术）是近几年提出的一种新的水稻直播种植技术，该技术改变了传统的开沟、起畦、播种、覆土、镇压等水稻直播联合作业形式，将水稻直播种植作业分成室内的工厂加工和室外田间的作业两步进行。应用该技术能够实现精细农业和订单农业生产，使种绳捻制作业在空间上不受土壤及其他条件限制、时间上不受农时季节约束，具有节约成本增加效益的作用，并实现田间作业的简单化和轻型化。本论文在对国内外水稻直播种植技术研究的基础上，根据本课题组新提出的“水稻种绳多物料直播种绳技术”，研制了一种水稻种绳捻制机，并进行了试验研究，研究成果对推动水稻直播种植新技术的应用具有重要意义。
论文取得的主要研究成果及结论如下：
（1）明确水稻种绳多物料直播种植技术的工艺流程。进行了肥料和除草剂的用量、位置等对水稻出苗率、苗高和幼苗期行间杂草密度的影响试验，确定了适合于该技术的被包容物料的用量和位置。在不卷入除草剂，稻种用量为单粒/穴，种距为30mm，肥料的用量为0.04g/穴，肥料与稻种的间距为15mm时，可显著提高水稻出苗率和苗高。进行了被包容物料物理机械特性的检测，试验结果为物料排放装置的选择和参数设计提供基础。
（2）对四种农用地膜（脱脂棉无纺布、农用牛皮纸纸膜、聚丙烯无纺布、纺粘聚乳酸无纺布）分别进行微观结构观察、红外光谱成分分析、抗拉强度检测、田间水稻出苗影响试验和降解试验研究。通过试验分析，筛选出适合作为种绳直播载体用的包容材料为纺粘聚乳酸无纺布，该材料具有可生物降解、对环境无污染、抗拉强度和断裂伸长率较高、对水稻出苗率无影响等优点。
（3）根据机械优化设计理论，确定了垂直双盘气吸式排种（肥）装置及配套梯形引导装置的设计方案。通过四因素二次回归通用旋转组合设计试验，得到了最优方案：排种轴转速为15.31r/min、稻种盘吸孔孔径为1.5mm、肥料盘吸孔孔径为2.0mm、吸气室的真空度为4.4kPa时，主要评价指标吸种合格率为86.32%，吸肥合格率为87.44%，保证了排种和排肥的准确率。通过对稻种、肥料在排放过程中的动力学分析，进行引导稻种、肥料装置的结构和参数设计，确定接种板和接肥料板的缓冲材料分别为密度60g/m2和80g/m2的纺粘聚乳酸无纺布，导板倾角均为50°。在排种器性能试验台上进行了引导定位性能试验，验证了稻种和肥料的排种（肥）和引导定位性能满足设计要求。
（4）进行了水稻种绳捻制装置的结构设计和控制系统的软硬件设计，包括控制系统的功能和控制流程分析、程序流程图的绘制、程序的编制、调试和装置的性能试验。确定了采用变频调速器实现对工作转速的调控，采用种绳盘摩擦力调节装置对种绳线速度进行调控的种绳捻制装置。通过两因素二次回归正交旋转组合设计试验，得到了当U型旋转框架的工作转速为420r/min，种绳盘轮毂摩擦力为7.9N时，捻绳平均线速度为0.13m/s，捻绳平均张力为14.4N，种绳捻制装置运转平稳，种绳无断裂现象。
（5）对水稻种绳捻制机进行样机性能试验。在最佳工作参数条件下进行种绳捻制作业，稻种间距合格率为81.4%，种肥间距合格率为84.4%；在捻制过程中，稻种泄漏率为3.85%、肥料泄漏率为1.96%、每延长米种绳的捻劲数为47个，各项指标均符合基本要求。
The rice direct sowing technology has played an important role in rice plantingtechnology in our country for the advantages of lower cost, water saving, less process, laborforce saving, and higher income, etc. The rice direct sowing technology with seed wrapped inpaper tape (RSTDST) was a new technology of rice direct sowing proposed in recent years. Itconverts the traditional process of rice direct sowing of furrow opening, seed metering, soilcovering and suppressing into two steps–first, wraping rice seed into paper tape in factory;second, laying the rice seed tape in paddy field. Precision agriculture and contract farming canbe realized by the application of the technology. The rice seed tape twisting is not affected byconditions of the soil and the season. It’s application can also decrease the production cost,increase income and simplify the operation in the field. Based on the review of rice directsowing technology development at home and abroad, a rice seed tape twisting machine wasdeveloped in according to the new technology of RSTDST proposed by the team, andrelative experiments were conducted. The results are significant for the application of ricedirect sowing technology.
The main achievements of this study are as following:
(1) The process of the rice seed tape direct sowing was determined where the seed wastreated with several materials. The experiments for the effects of fertilizer and herbicides inthe seed tape on the emergence rate, seedling height and the density of weeds in paddy fieldduring the seedling stage were carried out to determine the rate and position of the seedtreating materials in the tape. The results show that the germination rate and seedling heightwere significantly increased in the condition of single seed per hill, the distance betweenseeds of30mm, the rate of fertilizer of0.04g per hill, the distance of15mm between seed andfertilizer, and without herbicides applied in the tape. The physical and mechanical propertiesof the materials inclusived were tested to provide a theoretical basis for the selection andparameters design of the material-metering device.
(2) Four agricultural mulch films (non-woven absorbent cotton, agricultural kraft paper,non-woven polypropylene film, non-woven spun-bonded polylactic acid (PLA) film) usedcommonly were selected and the microstructure observation, FTIR spectral analysis, tensilestrength testing, the effect on rice seed germination and degradation property were testedrespectively. The non-woven.spun-bonded PLA film was selected as the appropriate carrierfor rice seed tape direct sowing technology It has the advantages of biodetadability,environmental pollution free, higher tensile strength and breaking elongation and, noinfluence on rice seed emergence rate, etc.
(3) The vertical double-disc pneumatic seed-metering and fertilizer-metering devicewith supporting trapezoidal guiding device were studied in according to the theories ofoptimization design. The optimum parameters were determined through the quadraticregression general rotatable combination test of four factors. The main evaluating indexes forthe device were qualified seed-sucking rate of86.32%and qualified fertilizer-sucking rate of87.44%under the seed-metering shaft speed of15.31r/min, seed disc sucking hole diameter of1.5mm, fertilizer disc sucking hole diameter of2.0mm, the sucking chamber vacuum of4.4kPa. In according to the kinetic analysis for seed and fertilizer in the process of sowing, thestructure and parameters of the guiding device for seed and fertilizer were determined and thecushioning materials pasted on seed board and fertilizer board were also determined to benon-woven spun-bonded PLA paper with density of60g/m2and80g/m2respectively, and the anglesof guiding board are both50°. The experiment of seed guiding and positioning was conductedon the test bed of metering device. The results showed that the performances of seed-meteringdevice, fertilizer-metering device, guiding and positioning device can meet the designrequirements.
(4) The analyses of the function and control flow of the system was performed, the flowchart was drafted, and the composition and debugging of the control system was carried out,and performance testing of the mechanism was conducted. On the rice seed tape twistingmachine, a altering frequency converter was used to regulate the rotating speed, a frictionadjusting device of the seed tape disc was utilized to control the circumferential velocity of theseed tape. The optimum parameters were determined through the quadratic regressionorthogonal rotatable combination test of two factors. The main evaluating indexes for themechanism were: peripheral velocity of0.13m/s, tension of14.4N at rotate speed of420r/min ofthe U-shaped rotating frame and the friction of7.9N of the seed tape disc. The seed tapetwisting mechanism runs smoothly with no fracture of seed tape.
(5) The overall performance of prototype of the rice seed tape twisting machine wascarried out.At the optimum operating parameters, the qualitied hill space of the seeds is81.4%, qualified distance between seed and fertilzer is84.4%, rice leakage rate is3.85%,fertilizer leakage rate is1.96%and the twisting number is47per meter of the rice seed tape.The results show that all the indexes can fulfill the basic requirements.
论文取得的主要研究成果及结论如下：
（1）明确水稻种绳多物料直播种植技术的工艺流程。进行了肥料和除草剂的用量、位置等对水稻出苗率、苗高和幼苗期行间杂草密度的影响试验，确定了适合于该技术的被包容物料的用量和位置。在不卷入除草剂，稻种用量为单粒/穴，种距为30mm，肥料的用量为0.04g/穴，肥料与稻种的间距为15mm时，可显著提高水稻出苗率和苗高。进行了被包容物料物理机械特性的检测，试验结果为物料排放装置的选择和参数设计提供基础。
（2）对四种农用地膜（脱脂棉无纺布、农用牛皮纸纸膜、聚丙烯无纺布、纺粘聚乳酸无纺布）分别进行微观结构观察、红外光谱成分分析、抗拉强度检测、田间水稻出苗影响试验和降解试验研究。通过试验分析，筛选出适合作为种绳直播载体用的包容材料为纺粘聚乳酸无纺布，该材料具有可生物降解、对环境无污染、抗拉强度和断裂伸长率较高、对水稻出苗率无影响等优点。
（3）根据机械优化设计理论，确定了垂直双盘气吸式排种（肥）装置及配套梯形引导装置的设计方案。通过四因素二次回归通用旋转组合设计试验，得到了最优方案：排种轴转速为15.31r/min、稻种盘吸孔孔径为1.5mm、肥料盘吸孔孔径为2.0mm、吸气室的真空度为4.4kPa时，主要评价指标吸种合格率为86.32%，吸肥合格率为87.44%，保证了排种和排肥的准确率。通过对稻种、肥料在排放过程中的动力学分析，进行引导稻种、肥料装置的结构和参数设计，确定接种板和接肥料板的缓冲材料分别为密度60g/m2和80g/m2的纺粘聚乳酸无纺布，导板倾角均为50°。在排种器性能试验台上进行了引导定位性能试验，验证了稻种和肥料的排种（肥）和引导定位性能满足设计要求。
（4）进行了水稻种绳捻制装置的结构设计和控制系统的软硬件设计，包括控制系统的功能和控制流程分析、程序流程图的绘制、程序的编制、调试和装置的性能试验。确定了采用变频调速器实现对工作转速的调控，采用种绳盘摩擦力调节装置对种绳线速度进行调控的种绳捻制装置。通过两因素二次回归正交旋转组合设计试验，得到了当U型旋转框架的工作转速为420r/min，种绳盘轮毂摩擦力为7.9N时，捻绳平均线速度为0.13m/s，捻绳平均张力为14.4N，种绳捻制装置运转平稳，种绳无断裂现象。
（5）对水稻种绳捻制机进行样机性能试验。在最佳工作参数条件下进行种绳捻制作业，稻种间距合格率为81.4%，种肥间距合格率为84.4%；在捻制过程中，稻种泄漏率为3.85%、肥料泄漏率为1.96%、每延长米种绳的捻劲数为47个，各项指标均符合基本要求。
The rice direct sowing technology has played an important role in rice plantingtechnology in our country for the advantages of lower cost, water saving, less process, laborforce saving, and higher income, etc. The rice direct sowing technology with seed wrapped inpaper tape (RSTDST) was a new technology of rice direct sowing proposed in recent years. Itconverts the traditional process of rice direct sowing of furrow opening, seed metering, soilcovering and suppressing into two steps–first, wraping rice seed into paper tape in factory;second, laying the rice seed tape in paddy field. Precision agriculture and contract farming canbe realized by the application of the technology. The rice seed tape twisting is not affected byconditions of the soil and the season. It’s application can also decrease the production cost,increase income and simplify the operation in the field. Based on the review of rice directsowing technology development at home and abroad, a rice seed tape twisting machine wasdeveloped in according to the new technology of RSTDST proposed by the team, andrelative experiments were conducted. The results are significant for the application of ricedirect sowing technology.
The main achievements of this study are as following:
(1) The process of the rice seed tape direct sowing was determined where the seed wastreated with several materials. The experiments for the effects of fertilizer and herbicides inthe seed tape on the emergence rate, seedling height and the density of weeds in paddy fieldduring the seedling stage were carried out to determine the rate and position of the seedtreating materials in the tape. The results show that the germination rate and seedling heightwere significantly increased in the condition of single seed per hill, the distance betweenseeds of30mm, the rate of fertilizer of0.04g per hill, the distance of15mm between seed andfertilizer, and without herbicides applied in the tape. The physical and mechanical propertiesof the materials inclusived were tested to provide a theoretical basis for the selection andparameters design of the material-metering device.
(2) Four agricultural mulch films (non-woven absorbent cotton, agricultural kraft paper,non-woven polypropylene film, non-woven spun-bonded polylactic acid (PLA) film) usedcommonly were selected and the microstructure observation, FTIR spectral analysis, tensilestrength testing, the effect on rice seed germination and degradation property were testedrespectively. The non-woven.spun-bonded PLA film was selected as the appropriate carrierfor rice seed tape direct sowing technology It has the advantages of biodetadability,environmental pollution free, higher tensile strength and breaking elongation and, noinfluence on rice seed emergence rate, etc.
(3) The vertical double-disc pneumatic seed-metering and fertilizer-metering devicewith supporting trapezoidal guiding device were studied in according to the theories ofoptimization design. The optimum parameters were determined through the quadraticregression general rotatable combination test of four factors. The main evaluating indexes forthe device were qualified seed-sucking rate of86.32%and qualified fertilizer-sucking rate of87.44%under the seed-metering shaft speed of15.31r/min, seed disc sucking hole diameter of1.5mm, fertilizer disc sucking hole diameter of2.0mm, the sucking chamber vacuum of4.4kPa. In according to the kinetic analysis for seed and fertilizer in the process of sowing, thestructure and parameters of the guiding device for seed and fertilizer were determined and thecushioning materials pasted on seed board and fertilizer board were also determined to benon-woven spun-bonded PLA paper with density of60g/m2and80g/m2respectively, and the anglesof guiding board are both50°. The experiment of seed guiding and positioning was conductedon the test bed of metering device. The results showed that the performances of seed-meteringdevice, fertilizer-metering device, guiding and positioning device can meet the designrequirements.
(4) The analyses of the function and control flow of the system was performed, the flowchart was drafted, and the composition and debugging of the control system was carried out,and performance testing of the mechanism was conducted. On the rice seed tape twistingmachine, a altering frequency converter was used to regulate the rotating speed, a frictionadjusting device of the seed tape disc was utilized to control the circumferential velocity of theseed tape. The optimum parameters were determined through the quadratic regressionorthogonal rotatable combination test of two factors. The main evaluating indexes for themechanism were: peripheral velocity of0.13m/s, tension of14.4N at rotate speed of420r/min ofthe U-shaped rotating frame and the friction of7.9N of the seed tape disc. The seed tapetwisting mechanism runs smoothly with no fracture of seed tape.
(5) The overall performance of prototype of the rice seed tape twisting machine wascarried out.At the optimum operating parameters, the qualitied hill space of the seeds is81.4%, qualified distance between seed and fertilzer is84.4%, rice leakage rate is3.85%,fertilizer leakage rate is1.96%and the twisting number is47per meter of the rice seed tape.The results show that all the indexes can fulfill the basic requirements.
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