Design of and experiment on fresh corn flexible picking and damage-free collectting harvest header

doi:10.6048/j.issn.1001-4330.2024.01.024

Abstract

Abstract:

【Objective】 A flexible harvesting and low-destructive header harvesting platform for fresh-food corn is to be designed. This finding can provide reference for mechanical harvesting loss reduction of fresh corn. 【Methods】 A two-stage transitional knife rolls was designed. Kinematic analysis of picking process was carried out to get the size and working parameters range of knife rolls and puller belt. Through theoretical analysis,the range of center distance of cutting knife rolls. Through discrete element simulation based on Hertz-Mindlin with bonding contact model,the suitable value of center distance of knife rolls. The knife rolls was assembled with staggered knife. It effectively alleviated the problem of high impurity content caused by excessive broken stalks. Through fatigue resistance test on two different kinds of rubber poking belts,and it was concluded. 【Results】 Designed a flexible harvesting and low-destructive header harvesting platform for fresh food corn.The main failure modes of rubber poking belts were wear of inner ring drive teeth,fracture of poking belt body and fatigue opening of outer ring poking teeth,and better wear and fatigue resistance of nitrile rubber poking belts with zinc oxide. A low-loss heading device was designed to effectively prevent damage caused by impact of causal spikes on stirrer blades,and the grain breakage rate was reduced by 0.08%. Through field orthogonal test and optimization,it was concluded that the forward speed of the machine was 7.2 km/h,the center distance of the knife rolls was 103 mm and the speed of the knife rolls was 700 r/min. 【Conclusion】 The average grain breakage rate and the average impurity content are 0.368% and 0.43%,respectively after optimization,which are better than the industry standard.

Key words: fresh corn; cab flexible picking; knife rolls; low-damage collecting; fatigue resistance test

摘要：

【目的】设计一种鲜食玉米柔性采摘低损集穗收获割台,为鲜食玉米机械收获减损提供参考。【方法】设计一种两级过渡切削式拉茎辊,对摘穗过程进行运动学分析,拉茎辊与拨禾带尺寸及工作参数范围及切削式拉茎辊中心距取值范围91.65~107.00 mm,基于Hertz-Mindlin with bonding接触模型的离散元仿真分析拉茎辊中心距合适值在102 mm左右及拉茎辊采用交错刀式装配,以便有效减少因茎秆被扯断导致含杂率高。测试两种不同材质橡胶拨禾带耐疲劳性及橡胶拨禾带主要失效形式。【结果】设计了一种柔性采摘低损集穗收获割台,橡胶拨禾带主要失效形式为内圈传动齿磨损、拨禾带体断裂和外圈拨禾齿疲劳开胶,加氧化锌的丁腈橡胶拨禾带有更好抗磨损和抗疲劳性能。有效防止了因果穗磕碰搅龙叶片导致的籽粒损伤,在试验中籽粒破损率减小了0.08%。机器前进速度为7.2 km/h,拉茎辊中心距为103 mm,拉茎辊转速为700 r/min时作业效果最好。【结论】优化后试验平均籽粒破损率为0.368%,平均含杂率为0.43%,优于行业标准。

关键词: 鲜食玉米, 柔性采摘, 切削式拉茎辊, 低损集穗, 耐疲劳性测试

CLC Number:

S225.51

WANG Shanbo, Alimu Maimaitituerxun, LI Qianxu, DU Zhigao, ZHANG Wei. Design of and experiment on fresh corn flexible picking and damage-free collectting harvest header[J]. Xinjiang Agricultural Sciences, 2024, 61(1): 217-229.

王善博, 阿力木·买买提吐尔逊, 李谦绪, 杜志高, 张伟. 鲜食玉米柔性采摘低损集穗收获割台设计与试验[J]. 新疆农业科学, 2024, 61(1): 217-229.

Figures/Tables 23

Fig.1 Structure diagram of fresh corn harvester header Note:1.Fresh corn picking device;2.Collecting device;3. Stirrer conveyor;4.Outlet;5.Divided harvest cover;6.Harvest protectiving cover;7.Droping prevention of corn ears;8.Divider

Fig.2 Fresh corn picking device 1.Belt guiding;2.Tensioning device;3.Slave wheel;4.Spike picker board;5.Main body;6.Active wheel;7.Harvesting belt;8.Gearboxes;9. Fixed knife of Preventing blockade;10.Cutting-type stem pulling rollers

Fig.3 ear picking board device

Fig.4 Working schemaic diagram of harvesting belt

Fig.5 Results comparison of fatigue resistance test

Fig.6 Structure diagram of two levels of transitional cutting-type stem-pulling rollers

Fig.7 Diagram of stem-pulling rollers

Fig.8 Analysis of instant state in working process of cutting-type stem-pulling rollers

Tab.1 Simulation model parameters

项目 Item	参数 Parameter	数值 Numerical value
玉米茎秆 Corn stalks	泊松比	0.4
	密度(N·m³)	1 060
	弹性模量(Pa)	4.8×10⁸
结构钢 Structural steel	泊松比	0.3
	密度(N·m³)	7 865
	弹性模量(Pa)	7.5×10¹⁰
玉米茎秆与玉米茎秆 Corn stalks and corn stalks	恢复系数	0.485
	静摩擦系数	0.142
	滚动摩擦系数	0.078
玉米茎秆与结构钢 Corn stalks and structural steel	恢复系数	0.663
	静摩擦系数	0.226
	滚动摩擦系数	0.119
粘结模型参数 Adhesive model parameters	单位面积法向刚度 (N/m³)	9.361×10⁷
	单位面积切向刚度 (N/m³)	9.845×10⁷
	临界法向应力(Mpa)	8.72
	临界切向应力(Mpa)	7.5
	粘结半径(mm)	1.2

Fig.9 Discrete element model of cornstalk

Fig.10 Pulling stem effect of simulation

Fig.11 Variation of bonds quantity with time

Fig.12 Maize cob collection diagram of previous harvesters Note:The function of the plucking belt is to move the stems and ears backwards,the axis direction of the agitator is the vertical direction of the machine's forward direction,the stirring dragon horizontally aggregates and transports the harvested fruit clusters,the process in which the harvested fruit ears are gathered from various picking devices is called the gathering process.

Fig.13 Low-damage maize cob collection diagram

Fig.14 Corn cob damage-free collection device Note:1.Hydraulic motor;2.Baffle conveyor;3.Tensioning device;4.Active roller bearing

Tab.2 Tset factors and codes

水平 Level	因素Factor
水平 Level	A(km/h)	B(mm)	C(rad/min)
-1	7	99	700
0	8	102	800
1	9	105	900

Tab.3 Test scheme and results

序号 Serial number	试验因素 Test factors			Z (%)	H (%)
序号 Serial number	A	B	C	Z (%)	H (%)
1	0	-1	1	0.64	2.56
2	0	0	0	0.38	0.81
3	0	0	0	0.42	0.79
4	0	0	0	0.45	0.81
5	-1	0	-1	0.33	0.39
6	0	0	0	0.42	0.77
7	0	1	1	0.65	0.91
8	-1	1	0	0.55	0.42
9	0	0	0	0.44	0.83
10	1	1	0	0.74	0.56
11	1	0	1	0.81	1.62
12	-1	0	1	0.57	0.75
13	1	0	-1	0.52	0.81
14	0	-1	-1	0.41	1.52
15	1	-1	0	0.64	1.98
16	0	1	-1	0.45	0.36
17	-1	-1	0	0.48	1.72

Tab.4 results test

序号 Serial number	籽粒破损率 Grain damage rate(%)
1	0.45
2	0.44
3	0.46
4	0.47
5	0.42

Fig.15 Test and working effects of equipment

Tab.5 Variance analysis for the damage rate of corn kernels and the rate of impurity

方差来源 Variance source	Z		H
方差来源 Variance source	F	P	F	P
模型 Model	32.39	<0.000 1^**	34.15	<0.000 1^**
A	79.1	<0.000 1^**	162.49	<0.000 1^**
B	6.29	0.040 5^*	20.42	0.002 7^**
C	119.82	<0.000 1^**	97.8	<0.000 1^**
AB	0.234	0.643 3	2.76	0.140 4
AC	0.650 1	0.446 6	7.73	0.027 3^*
BC	0.234	0.643 3	0.296 5	0.603
A²	44.01	0.000 3^**	7.57	0.028 4^*
B²	28.2	0.001 1^**	2.67	0.146 1
C²	5.44	0.052 4	4.07	0.083 5
失拟项 Misfit term	1.78	0.289 6	17.26	0.009 4^*

Fig.16 Influences of various experimental factors on the damage rate of corn kernels and the rate of impurity

Tab.6 results of validation test

序号 Serial number	籽粒破损率 Grain damage rate (%)	含杂率 Trash content (%)
1	0.36	0.44
2	0.38	0.40
3	0.36	0.43
4	0.35	0.51
5	0.39	0.37

Fig.17 Optimized operation effect

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