基于三维离散元法的玉米脱粒过程分析方法研究
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摘要
玉米是典型的多用途高产作物，经过多年发展，我国玉米的种植面积，已成为仅次于水稻的第二大作物，年产玉米近一亿五千万吨。由于各地地理和气候等原因，大部分玉米都是收获晾晒后，再进行脱粒操作。因此，玉米脱粒机的使用非常广泛，对于保证玉米收后质量和农民增收起着重要作用。
由于脱粒机工作过程的复杂性，到目前为止国内外对玉米脱粒机的研究和设计，大都采用试验方法、统计分析方法或传统连续介质力学的分析方法，本文采用离散元法研究玉米的脱粒过程。在综述了玉米脱粒机原理和结构以及国内外对于脱粒过程研究现状的基础上，以一种滚筒式玉米脱粒机为研究对象，通过对玉米果穗的物理力学性质测试分析、玉米果穗建模方法的研究、三维离散元法边界建模软件的研制、玉米脱粒过程的离散元法计算方法的研究，研制了基于三维离散元法的玉米脱粒过程仿真分析软件，进行了玉米脱粒过程台架试验，并采用研制的软件对该过程进行了仿真分析，通过仿真结果与试验结果的对比，验证了所建立方法和软件的可行性和有效性，为玉米脱粒过程的研究和脱粒机的优化设计建立了一种新方法，本文的主要工作和结论如下。
1）对先锋8号玉米果穗的物理力学性质进行了测试分析，包括玉米果穗长度、果穗行数、行粒数、果穗大小端直径、玉米芯大小端直径、行内籽粒偏移角度、行间籽粒偏移量，各段玉米果穗的参数以及玉米籽粒和玉米芯的密度和含水率等，并分别测试了各段玉米果穗的玉米籽粒与玉米芯连接处的刚度系数和连接力，提出了玉米籽粒与玉米芯连接力的计算方法和连接的破坏准则，为采用离散元法仿真分析玉米的脱粒过程奠定基础。
2）在深入研究玉米果穗、玉米籽粒和玉米芯结构的基础上，提出了基于颗粒聚合体的玉米果穗分析模型建模方法，通过所建立的分析模型与实际玉米果穗的对比，验证了提出的玉米果穗分析模型建模方法的可行性。
3）在深入研究UG软件及其二次开发方法、研究规则曲面类型及信息提取方法的基础上，研制了基于UG软件的三维离散元法边界建模软件，通过所建立玉米脱粒机分析模型的初步验证，证明了该边界建模软件的可行性和有效性。
4）对玉米脱粒过程的离散元法计算方法进行了深入的研究，提出了分析玉米脱粒过程的离散元法分析方法，主要包括：颗粒间及颗粒与边界间的邻居搜索和接触检测方法、颗粒间及颗粒与边界间的接触力计算方法、玉米果穗内部的接触检测和受力计算方法，颗粒运动的求解方法等。
5）基于面向对象技术，研制出基于离散元法的玉米脱粒过程仿真分析软件，进行了软件的需求分析、概要设计和详细设计，对软件的各个功能进行了测试，包括对玉米果穗模型与边界的接触过程测试，邻居搜索和接触检测方法的测试以及对玉米脱粒过程仿真分析、脱粒性能分析功能的测试，通过给出的测试用例，证明了研制的脱粒过程仿真分析软件的可行性和有效性。
6）以一种滚筒式玉米脱粒机为对象，进行了玉米脱粒过程的台架试验，研究不同因素对玉米脱粒过程和脱粒机性能的影响，得到如下结论：
①不同滚筒转速下（122.7~317.15r/min），试验脱净率随滚筒转速的提高而增加，转速低于250r/min时，脱净率的受转速影响较大，脱粒效果很不稳定；转速高于250r/min时，脱净率达96%以上，此时脱净率的变化受转速影响变小，脱粒效果明显变好。不同果穗投入量下（5~20穗）及不同果穗部位下（上段、中段和下段），脱净率的变化波动较小；
②不同转速下，籽粒数量的分布沿脱粒机滚筒轴向逐步减少，滚筒轴线两端脱落籽粒数量差别较大，而在最后一段的分离率随转速的增加而增加。不同果穗投入量下，籽粒的分布基本沿滚筒轴向逐步下降，脱粒机滚筒转速、果穗投入量以及果穗部位对籽粒的轴向分布曲线影响均比较小。
7）采用自主研制的三维离散元法仿真分析软件，对玉米脱粒过程进行了仿真分析，并将仿真结果与试验结果进行了对比，得到如下结论：
①不同滚筒转速下（65.5~500r/min），仿真脱净率随滚筒转速的提高而增加，这一变化趋势与台架试验结果相同。当滚筒转速低于252.10r/min时，仿真脱净率略低于试验结果；当滚筒转速为122.70r/min时，两者误差最大为9.99%；当转速提高后，仿真结果略高于台架试验结果，且脱净率变化的波动很小。不同果穗投入量下，仿真脱净率随投入量的增加而增加，这一变化趋势与台架试验相同。脱净率受果穗投入量及果穗部位的影响也较小；
②不同滚筒转速下，仿真时脱落籽粒数量分布沿滚筒轴向减少，并且仿真和试验的分布曲线在变化规律上大致相同，但多数情况下两者在轴向第1段籽粒分布差距相对较大（误差在10%左右）。脱粒机滚筒转速、果穗投入量以及果穗部位对籽粒的轴向分布曲线影响均比较小；
③仿真输入参数在实测范围内选取时，玉米果穗的脱净率随颗粒刚度系数的增大而增大；3种摩擦系数下，脱净率均大于98%，脱净率受摩擦系数的影响较小；
④仿真输入参数在实测范围内选取时，不同刚度系数及摩擦系数下，仿真时脱落籽粒分布沿滚筒轴向减少，这一变化趋势与台架试验结果相同；
⑤改变脱粒机CAD模型后，不同滚筒转速下，仿真脱净率随滚筒转速的提高而增加，脱落籽粒分布沿滚筒轴向逐步减少，这一变化趋势与改变前仿真结果相同。由于改变脱粒机的结构，加大了钉齿对玉米果穗的打击机会，使不同转速下的仿真脱净率均高于改变前结果，以及滚筒第1段分布籽粒数量百分比均高于改变前结果。
8）通过软件仿真与试验结果的对比分析，初步证明了本文所建立方法和软件的可行性和有效性，为玉米脱粒过程分析和脱粒机的优化设计建立了一种新方法。
Corn is a typical multipurpose and high yield crop. After years of development, the cornplanting area of China has become the second largest crops after rice, the annual output ofcorn is nearly a billion fifty million tons. Due to local geography, climate and other factors,most of corn will be dried first and then threshed after harvesting. Therefore, there is awildly use of corn thresher, and it plays an important role to guarantee the quality of cornafter harvesting and also to improve the farmers’income.
However, due to the complexity of working process, up to now most of the researchesand designs of corn thresher were carried out by experimental methods, statistical analysismethods or traditional continuum mechanics analysis methods at home and abroad. In thispaper, the discrete element method (DEM) is adopted to research the corn threshing process.Based on the review of the principle and the structure of the corn threshers as well as theresearch status of the corn threshing, a drum type corn thresher is taken as research object. Inthis paper the physical and mechanical properties of the corn ears is tested, the modelingmethod of corn ears is researched, the3D DEM boundary modeling software is developed,researches the DEM calculation methods of the corn threshing process is researched. Basedon above work, a corn threshing process simulation analysis software using3D DEM isdeveloped. The simulation analysis of the corn threshing process is carried out by using thissoftware and the bench test of the corn threshing process is finished. By comparing thesimulation results with the test results, the feasibility and effectiveness of the new methodare validated. Thus this paper presents a novel method for the research of the corn threshingprocess and the optimal design of the corn thresher. The main work and results of this paperare as follows.
1) The physical and mechanical properties of the corn ear of xianfeng8have been tested,including corn ear length, corn ear both ends of diameter, corn cob both ends of diameter,corn ear row number, kernel number per row, kernel angle per row, kernel offset between therows, parameters of each segment corn ear, density and moisture content of the kernel andthe cob, connection stiffness coefficient and connection force between the kernel and the cobof each segment and so on. The calculation method of the connection force between thekernel and the cob and the conditions for the corn kernel threshing are proposed. Thus wehave laid the foundation for using the DEM to analyze the corn threshing process.
2) Based on deep researching of the structure of corn ear, cob and kernel, the modelingmethod of corn ears based on particles agglomerate is proposed. By comparing the corn ears’entities with the analysis models, the feasibility of the new method is validated.
3) Based on deep researching of the UG software and the second development,researching of the method of getting boundary information for regular surface, the3D boundary modeling software for corn thresher based on UG software is developed. Bybuilding the corn thresher’s analysis model, the feasibility and effectiveness of the boundarymodeling software are validated.
4) The DEM analysis theory of corn threshing process has been established, and theDEM calculating method of corn threshing process has been deeply researched, includingthe neighbor search collision detecting methods and the contact force calculation methodsbetween the particles and between the particle and the boundary, the collision detectingmethods and force calculation methods in one corn ear, and the calculation method forparticle motion.
5) With the application of object-oriented technology, a corn threshing processsimulation analysis software based on3D DEM is developed after the requirements analysisand the preliminary design as well as the detailed design. The following functions are tested,including the connecting process function test between corn ear models and the boundaries,the methods of the neighbor search collision detecting and the function of performancepresentation function of the threshing machines. From the test cases, the feasibility andeffectiveness of analysis on the threshing simulation software is verified.
6) Through the bench experiments of the drum-type corn threshing machine, the impactof different factors on the corn threshing process and the threshing machines performance isstudied. Conclusions are as follows.
①Threshed rate during the test increases with increasing rotary speed of the rollerwithin65.5~500r/min. Rotary speed of the roller less than250r/min has a great impact onthreshed rate which is then very unstable. Threshing performance is greatly improved andthe threshed rate reaches96%when rotary speed of the roller is more than250r/min. Rotaryspeed of the roller on threshed rate is not significant and it also adds stability to threshingperformance. The corn ear number between5to20and the different parts of the corn earsfrom top to bottom don’t affect largely on threshed rate.
②It has a less threshed kernels distribution axially in different rotary speed of theroller with different rotary speed of the roller. There are big differences quantitativelybetween the first part and the last part of the cylinder. The threshed rate in last part of thecylinder increases with increasing rotary speed of the roller. In addition, it has a less fallenkernels distribution axially in different rotary speed of the roller with different numbers ofthe corn ears. There is few differences of the distribution curve of the fallen kernels axiallywith different rotary speed of the roller, different numbers of the corn ears and different partsof the corn ears.
7) Simulation analysis on the working process of corn threshing is conducted by thesimulation analysis software based on DEM developed independently. And the results acquired by experiment of corn threshing machine are analyzed contrastively. Conclusionsare as follows.
①It is the same that threshed rate during the test increases with increasing rotary speedof the roller within65.5~500r/min. Threshed rates in the simulation analysis are just underthose in the bench experiments when the rotary speed of the roller is less than252.10r/min.The maximum discrepancy is9.99%in122.70r/min. Threshed rates in the simulationanalysis are higher than those in the bench experiments as the rotary speed of the rollerincreases. It also follows the same trend with the bench experiments that threshed ratesincrease with increasing numbers of corn ears in simulation tests. The number of the cornears and the different parts of the corn ears don’t play an important role on the threshingprocess.
②It has a less shedding kernel distribution axially in the simulation analysis and thedistribution of the threshed kernel is similar to that in the bench experiments. Mostly, thebiggest error (about10%) occurs in the first part of the cylinder. There is few differences ofthe distribution curve of the fallen kernels axially with different rotary speed of the roller,different numbers of the corn ears and different parts of the corn ears.
③The threshed rate increases with the increasing stiffness coefficient while thesimulation parameters are acquired in the physical and mechanical tests. The threshed rate isless affected by the friction coefficient in the selected three friction coefficients as thethreshed rate is all higher than98%.
④It also follows basically the same trend with the bench experiments that it has a lessthreshing kernels distribution axially with different stiffness coefficient and frictioncoefficient while the simulation parameters are acquired in the physical and mechanicaltests.
⑤It is the same for the changed threshing machine CAD model in the simulation withthe original model that the threshed rate increases with increasing rotary speed of the rollerand it has a less shedding kernel distribution axially. The changed threshing machine modelincreases the chance of collision between nail teeth and corn ears, so the threshed rates withthe changed threshing machine model are higher than those in the original model in thesimulation and there are more kernels in the first part of the cylinder.
8) By comparing the simulation results with the test results, the feasibility andeffectiveness of the new method and the corn threshing process simulation analysis softwareis validated. Thus we have put forward a novel method for the research of the corn threshing a nd the optimal design of the corn thresher.
由于脱粒机工作过程的复杂性，到目前为止国内外对玉米脱粒机的研究和设计，大都采用试验方法、统计分析方法或传统连续介质力学的分析方法，本文采用离散元法研究玉米的脱粒过程。在综述了玉米脱粒机原理和结构以及国内外对于脱粒过程研究现状的基础上，以一种滚筒式玉米脱粒机为研究对象，通过对玉米果穗的物理力学性质测试分析、玉米果穗建模方法的研究、三维离散元法边界建模软件的研制、玉米脱粒过程的离散元法计算方法的研究，研制了基于三维离散元法的玉米脱粒过程仿真分析软件，进行了玉米脱粒过程台架试验，并采用研制的软件对该过程进行了仿真分析，通过仿真结果与试验结果的对比，验证了所建立方法和软件的可行性和有效性，为玉米脱粒过程的研究和脱粒机的优化设计建立了一种新方法，本文的主要工作和结论如下。
1）对先锋8号玉米果穗的物理力学性质进行了测试分析，包括玉米果穗长度、果穗行数、行粒数、果穗大小端直径、玉米芯大小端直径、行内籽粒偏移角度、行间籽粒偏移量，各段玉米果穗的参数以及玉米籽粒和玉米芯的密度和含水率等，并分别测试了各段玉米果穗的玉米籽粒与玉米芯连接处的刚度系数和连接力，提出了玉米籽粒与玉米芯连接力的计算方法和连接的破坏准则，为采用离散元法仿真分析玉米的脱粒过程奠定基础。
2）在深入研究玉米果穗、玉米籽粒和玉米芯结构的基础上，提出了基于颗粒聚合体的玉米果穗分析模型建模方法，通过所建立的分析模型与实际玉米果穗的对比，验证了提出的玉米果穗分析模型建模方法的可行性。
3）在深入研究UG软件及其二次开发方法、研究规则曲面类型及信息提取方法的基础上，研制了基于UG软件的三维离散元法边界建模软件，通过所建立玉米脱粒机分析模型的初步验证，证明了该边界建模软件的可行性和有效性。
4）对玉米脱粒过程的离散元法计算方法进行了深入的研究，提出了分析玉米脱粒过程的离散元法分析方法，主要包括：颗粒间及颗粒与边界间的邻居搜索和接触检测方法、颗粒间及颗粒与边界间的接触力计算方法、玉米果穗内部的接触检测和受力计算方法，颗粒运动的求解方法等。
5）基于面向对象技术，研制出基于离散元法的玉米脱粒过程仿真分析软件，进行了软件的需求分析、概要设计和详细设计，对软件的各个功能进行了测试，包括对玉米果穗模型与边界的接触过程测试，邻居搜索和接触检测方法的测试以及对玉米脱粒过程仿真分析、脱粒性能分析功能的测试，通过给出的测试用例，证明了研制的脱粒过程仿真分析软件的可行性和有效性。
6）以一种滚筒式玉米脱粒机为对象，进行了玉米脱粒过程的台架试验，研究不同因素对玉米脱粒过程和脱粒机性能的影响，得到如下结论：
①不同滚筒转速下（122.7~317.15r/min），试验脱净率随滚筒转速的提高而增加，转速低于250r/min时，脱净率的受转速影响较大，脱粒效果很不稳定；转速高于250r/min时，脱净率达96%以上，此时脱净率的变化受转速影响变小，脱粒效果明显变好。不同果穗投入量下（5~20穗）及不同果穗部位下（上段、中段和下段），脱净率的变化波动较小；
②不同转速下，籽粒数量的分布沿脱粒机滚筒轴向逐步减少，滚筒轴线两端脱落籽粒数量差别较大，而在最后一段的分离率随转速的增加而增加。不同果穗投入量下，籽粒的分布基本沿滚筒轴向逐步下降，脱粒机滚筒转速、果穗投入量以及果穗部位对籽粒的轴向分布曲线影响均比较小。
7）采用自主研制的三维离散元法仿真分析软件，对玉米脱粒过程进行了仿真分析，并将仿真结果与试验结果进行了对比，得到如下结论：
①不同滚筒转速下（65.5~500r/min），仿真脱净率随滚筒转速的提高而增加，这一变化趋势与台架试验结果相同。当滚筒转速低于252.10r/min时，仿真脱净率略低于试验结果；当滚筒转速为122.70r/min时，两者误差最大为9.99%；当转速提高后，仿真结果略高于台架试验结果，且脱净率变化的波动很小。不同果穗投入量下，仿真脱净率随投入量的增加而增加，这一变化趋势与台架试验相同。脱净率受果穗投入量及果穗部位的影响也较小；
②不同滚筒转速下，仿真时脱落籽粒数量分布沿滚筒轴向减少，并且仿真和试验的分布曲线在变化规律上大致相同，但多数情况下两者在轴向第1段籽粒分布差距相对较大（误差在10%左右）。脱粒机滚筒转速、果穗投入量以及果穗部位对籽粒的轴向分布曲线影响均比较小；
③仿真输入参数在实测范围内选取时，玉米果穗的脱净率随颗粒刚度系数的增大而增大；3种摩擦系数下，脱净率均大于98%，脱净率受摩擦系数的影响较小；
④仿真输入参数在实测范围内选取时，不同刚度系数及摩擦系数下，仿真时脱落籽粒分布沿滚筒轴向减少，这一变化趋势与台架试验结果相同；
⑤改变脱粒机CAD模型后，不同滚筒转速下，仿真脱净率随滚筒转速的提高而增加，脱落籽粒分布沿滚筒轴向逐步减少，这一变化趋势与改变前仿真结果相同。由于改变脱粒机的结构，加大了钉齿对玉米果穗的打击机会，使不同转速下的仿真脱净率均高于改变前结果，以及滚筒第1段分布籽粒数量百分比均高于改变前结果。
8）通过软件仿真与试验结果的对比分析，初步证明了本文所建立方法和软件的可行性和有效性，为玉米脱粒过程分析和脱粒机的优化设计建立了一种新方法。
Corn is a typical multipurpose and high yield crop. After years of development, the cornplanting area of China has become the second largest crops after rice, the annual output ofcorn is nearly a billion fifty million tons. Due to local geography, climate and other factors,most of corn will be dried first and then threshed after harvesting. Therefore, there is awildly use of corn thresher, and it plays an important role to guarantee the quality of cornafter harvesting and also to improve the farmers’income.
However, due to the complexity of working process, up to now most of the researchesand designs of corn thresher were carried out by experimental methods, statistical analysismethods or traditional continuum mechanics analysis methods at home and abroad. In thispaper, the discrete element method (DEM) is adopted to research the corn threshing process.Based on the review of the principle and the structure of the corn threshers as well as theresearch status of the corn threshing, a drum type corn thresher is taken as research object. Inthis paper the physical and mechanical properties of the corn ears is tested, the modelingmethod of corn ears is researched, the3D DEM boundary modeling software is developed,researches the DEM calculation methods of the corn threshing process is researched. Basedon above work, a corn threshing process simulation analysis software using3D DEM isdeveloped. The simulation analysis of the corn threshing process is carried out by using thissoftware and the bench test of the corn threshing process is finished. By comparing thesimulation results with the test results, the feasibility and effectiveness of the new methodare validated. Thus this paper presents a novel method for the research of the corn threshingprocess and the optimal design of the corn thresher. The main work and results of this paperare as follows.
1) The physical and mechanical properties of the corn ear of xianfeng8have been tested,including corn ear length, corn ear both ends of diameter, corn cob both ends of diameter,corn ear row number, kernel number per row, kernel angle per row, kernel offset between therows, parameters of each segment corn ear, density and moisture content of the kernel andthe cob, connection stiffness coefficient and connection force between the kernel and the cobof each segment and so on. The calculation method of the connection force between thekernel and the cob and the conditions for the corn kernel threshing are proposed. Thus wehave laid the foundation for using the DEM to analyze the corn threshing process.
2) Based on deep researching of the structure of corn ear, cob and kernel, the modelingmethod of corn ears based on particles agglomerate is proposed. By comparing the corn ears’entities with the analysis models, the feasibility of the new method is validated.
3) Based on deep researching of the UG software and the second development,researching of the method of getting boundary information for regular surface, the3D boundary modeling software for corn thresher based on UG software is developed. Bybuilding the corn thresher’s analysis model, the feasibility and effectiveness of the boundarymodeling software are validated.
4) The DEM analysis theory of corn threshing process has been established, and theDEM calculating method of corn threshing process has been deeply researched, includingthe neighbor search collision detecting methods and the contact force calculation methodsbetween the particles and between the particle and the boundary, the collision detectingmethods and force calculation methods in one corn ear, and the calculation method forparticle motion.
5) With the application of object-oriented technology, a corn threshing processsimulation analysis software based on3D DEM is developed after the requirements analysisand the preliminary design as well as the detailed design. The following functions are tested,including the connecting process function test between corn ear models and the boundaries,the methods of the neighbor search collision detecting and the function of performancepresentation function of the threshing machines. From the test cases, the feasibility andeffectiveness of analysis on the threshing simulation software is verified.
6) Through the bench experiments of the drum-type corn threshing machine, the impactof different factors on the corn threshing process and the threshing machines performance isstudied. Conclusions are as follows.
①Threshed rate during the test increases with increasing rotary speed of the rollerwithin65.5~500r/min. Rotary speed of the roller less than250r/min has a great impact onthreshed rate which is then very unstable. Threshing performance is greatly improved andthe threshed rate reaches96%when rotary speed of the roller is more than250r/min. Rotaryspeed of the roller on threshed rate is not significant and it also adds stability to threshingperformance. The corn ear number between5to20and the different parts of the corn earsfrom top to bottom don’t affect largely on threshed rate.
②It has a less threshed kernels distribution axially in different rotary speed of theroller with different rotary speed of the roller. There are big differences quantitativelybetween the first part and the last part of the cylinder. The threshed rate in last part of thecylinder increases with increasing rotary speed of the roller. In addition, it has a less fallenkernels distribution axially in different rotary speed of the roller with different numbers ofthe corn ears. There is few differences of the distribution curve of the fallen kernels axiallywith different rotary speed of the roller, different numbers of the corn ears and different partsof the corn ears.
7) Simulation analysis on the working process of corn threshing is conducted by thesimulation analysis software based on DEM developed independently. And the results acquired by experiment of corn threshing machine are analyzed contrastively. Conclusionsare as follows.
①It is the same that threshed rate during the test increases with increasing rotary speedof the roller within65.5~500r/min. Threshed rates in the simulation analysis are just underthose in the bench experiments when the rotary speed of the roller is less than252.10r/min.The maximum discrepancy is9.99%in122.70r/min. Threshed rates in the simulationanalysis are higher than those in the bench experiments as the rotary speed of the rollerincreases. It also follows the same trend with the bench experiments that threshed ratesincrease with increasing numbers of corn ears in simulation tests. The number of the cornears and the different parts of the corn ears don’t play an important role on the threshingprocess.
②It has a less shedding kernel distribution axially in the simulation analysis and thedistribution of the threshed kernel is similar to that in the bench experiments. Mostly, thebiggest error (about10%) occurs in the first part of the cylinder. There is few differences ofthe distribution curve of the fallen kernels axially with different rotary speed of the roller,different numbers of the corn ears and different parts of the corn ears.
③The threshed rate increases with the increasing stiffness coefficient while thesimulation parameters are acquired in the physical and mechanical tests. The threshed rate isless affected by the friction coefficient in the selected three friction coefficients as thethreshed rate is all higher than98%.
④It also follows basically the same trend with the bench experiments that it has a lessthreshing kernels distribution axially with different stiffness coefficient and frictioncoefficient while the simulation parameters are acquired in the physical and mechanicaltests.
⑤It is the same for the changed threshing machine CAD model in the simulation withthe original model that the threshed rate increases with increasing rotary speed of the rollerand it has a less shedding kernel distribution axially. The changed threshing machine modelincreases the chance of collision between nail teeth and corn ears, so the threshed rates withthe changed threshing machine model are higher than those in the original model in thesimulation and there are more kernels in the first part of the cylinder.
8) By comparing the simulation results with the test results, the feasibility andeffectiveness of the new method and the corn threshing process simulation analysis softwareis validated. Thus we have put forward a novel method for the research of the corn threshing a nd the optimal design of the corn thresher.
引文
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