垄作残膜捡拾及脱卸装置的研究
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摘要
随着地膜覆盖面积的扩大和覆膜年限的增长,滞留田间的残膜造成了农业环境的严重污染。使用机械回收残膜可以克服人工捡拾劳动强度大、有效回收率低的缺点,但现有残膜回收机具多根据经验设计,没有精确的部件理论研究为基础,存在捡拾性能不可靠、卸膜过程回带及工作部件严重磨损等问题。本论文以残地膜力学性能测试为基础,采用理论分析、模糊优化设计、虚拟样机仿真与试验验证相结合的方法对杆齿式残膜回收机具的关键部件进行了深入的研究。主要研究成果包括：
1)对残膜的力学性能进行测试和分析。与0.012mm的残膜相比,0.006mm的残膜纵向拉伸载荷减小37.59%横向拉伸载荷减小38.68%,直角撕裂载荷减小29.60%,纵向拉伸断裂延伸率减小20.35%,横向拉伸断裂延伸率减小26.27%,直角撕裂断裂延伸率减小35.09%。使用90天、厚度为0.012mm的残膜(不加耐候剂)纵向、横向抗拉强度至少降低40.43%,最小断裂伸长率减少43.01%。
2)采用非线性有限元法对拾膜过程中地膜与弹齿的变形及受力情况进行了分析。利用高速摄像系统测试了地膜与弹齿的变形情况。结果表明地膜和弹齿在捡拾过程中的变形量影响弹齿拾膜率,变形量与弹齿末端速度以及机具行进速度有关。
3)研究了托膜铲性能影响因素,利用有限元法对托膜铲的强度及变形情况进行了分析,建立了托膜铲模糊综合评价模型,通过试验优化了结构参数和工作参数,确定托膜铲最优入土角度为260、最优栅条数2根。
4)对滑道-弹齿式拾膜机构进行了运动学和动力学分析,建立了机构的运动学和动力学模型。运用Matlab软件的曲线拟合功能生成弹齿末端运动轨迹模型,按照结构关系得出滑道的数学模型,为滑道轮廓的数字化加工提供了条件。
5)采用多目标模糊优化确定了拾膜机构主要结构参数：滑道最小基圆半径为55mm,滚子半径为15mm,连接板长度为120mm,摆杆长度为70mm。运用ADAMS仿真软件对机构进行运动仿真,仿真结果表明机构满足拾膜要求。根据台架试验确定了拾膜机构的工作参数。
6)对搂齿卸膜机构进行运动分析,建立了各构件运动和受力情况的数学模型；按照预定轨迹对搂齿卸膜机构进行优化,确定了各部分结构参数：曲柄与摇杆支座距离为160mm,曲柄长度为80mm,搂膜连杆长度为140mm,摇杆长度为130mm,搂膜杆齿长度为420mm,机架与x轴正向夹角为16°,搂膜连杆与搂膜杆齿所夹锐角为260。对优化后的搂齿卸膜机构进行了运动学和动力学仿真,仿真结果表明机构满足卸膜要求。
7)制造了杆齿式残膜回收机的物理样机,通过田间试验证明,样机的作业质量满足技术要求。
With expand of the covering area and growth of age of plastic film, the residual plastic film left in fields caused serious pollution of the agriculture environment. Mechanical recycling plastic film can overcome shortcomings of the great labor intensity and low effective rate using artificial picking up. However the existing plastic film recycling equipments are generally design by experiences and have no precise theoretical researches for components, there are some issues including unreliable picking up performance and unloading film processes "back-carry" and serious wear of working parts. This paper researched deeply the key components of the pole-tooth residual film collecting machine by using theoretical analysis, the fuzzy optimization design, the virtual prototype simulation and experimental verification. Main research achievements include:
1) The experiment and analysis about the changes of the mechanical properties of residual film have been carried on. Compared with the0.012mm residual film, the longitudinal tensile load of the0.006mm residual film decreases37.59%, the transverse tensile load decreases38.68%, the right angle tear load decreases29.60%, the longitudinal tensile fracture elongation decreases20.35%, the transverse tensile fracture elongation decreases26.27%, the right angle tear fracture elongation decreases35.09%. The longitudinal and transverse tensile strength of0.012mm residual plastic films used90days (without weather resistant agent) reduced by at least40.43%, the smallest fracture elongation reduced by at least43.01%.
2) The deformation and stress distribution of the residual film and spring tooth were analyzed by nonlinear finite element method in the process of picking up film mulch. Using high speed camera system to test the deformation and stress distribution. Results show that the deformations of the film and spring tooth in the picked up process influence the residual film collecting rate of the spring-tooth, the deformations are related to the speed of the spring-tooth end and machine speed.
3) The influencing factors of the lifting film shovel's performance were researched in the paper. According to the working resistance model of the lifting film shovel, the strength and deformation of the shovel were analyzed by using the finite element method. The fuzzy comprehensive evaluation model of the lifting film shovel was established, the structure parameters and operating parameters were optimized by the experiment, the optimal entering soil angle of260and numbers of2bars of the lifting film shovel were gained.
4) The kinematics and dynamics analysis of slide-way spring-tooth collecting residual film mechanism were done, and the kinematics and dynamics models were established. The spring tooth end trajectory model was received by using the curve fitting of Matlab software, and the mathematical model of the slide-way was obtained according to the structural relationship, it provided the conditions for the digital processing of slide way profile.
5) By Multi-objective fuzzy optimization, the main structural parameters of the pick-up residual plastic film mechanism were identified:the slid-way minimum basic circle radius is55mm, the roller radius is15mm, the plate length is120mm, the pendulum length is70mm. Using ADM AS software, the kinematics and dynamics simulations of the fuzzy optimized collecting residual film mechanism were done, the results of simulation are consistent with the requirements of the picking up film. The working parameters were optimized by bench test of spring-tooth collecting residual film mechanism.
6) The movement analyses of the raking and unloading plastic film mechanism were done, and the mathematical models of the components' movement and stress were gained. According to the desired trajectory, the raking and unloading plastic film mechanism was optimized, and the parameters of parts were determined:the distance between crank and rocker is160mm, the crank length is80mm, the link length for scratching film is140mm, the rocker length is130mm, the tooth bar length is420mm, the angle between the frame and the x-axis positive direction is16°, the acute angle between the link length for scratching film and the tooth bar is26°.The kinematics and dynamics simulations of the optimized unloading residual film mechanism were done, the results of simulation are consistent with the requirements of the unloading film.
7) The pole tooth physical prototype of the residual film recycling machine was made, the field experiment has proved that the work qualities of the physical prototype meet the technical requirements.
1)对残膜的力学性能进行测试和分析。与0.012mm的残膜相比,0.006mm的残膜纵向拉伸载荷减小37.59%横向拉伸载荷减小38.68%,直角撕裂载荷减小29.60%,纵向拉伸断裂延伸率减小20.35%,横向拉伸断裂延伸率减小26.27%,直角撕裂断裂延伸率减小35.09%。使用90天、厚度为0.012mm的残膜(不加耐候剂)纵向、横向抗拉强度至少降低40.43%,最小断裂伸长率减少43.01%。
2)采用非线性有限元法对拾膜过程中地膜与弹齿的变形及受力情况进行了分析。利用高速摄像系统测试了地膜与弹齿的变形情况。结果表明地膜和弹齿在捡拾过程中的变形量影响弹齿拾膜率,变形量与弹齿末端速度以及机具行进速度有关。
3)研究了托膜铲性能影响因素,利用有限元法对托膜铲的强度及变形情况进行了分析,建立了托膜铲模糊综合评价模型,通过试验优化了结构参数和工作参数,确定托膜铲最优入土角度为260、最优栅条数2根。
4)对滑道-弹齿式拾膜机构进行了运动学和动力学分析,建立了机构的运动学和动力学模型。运用Matlab软件的曲线拟合功能生成弹齿末端运动轨迹模型,按照结构关系得出滑道的数学模型,为滑道轮廓的数字化加工提供了条件。
5)采用多目标模糊优化确定了拾膜机构主要结构参数：滑道最小基圆半径为55mm,滚子半径为15mm,连接板长度为120mm,摆杆长度为70mm。运用ADAMS仿真软件对机构进行运动仿真,仿真结果表明机构满足拾膜要求。根据台架试验确定了拾膜机构的工作参数。
6)对搂齿卸膜机构进行运动分析,建立了各构件运动和受力情况的数学模型；按照预定轨迹对搂齿卸膜机构进行优化,确定了各部分结构参数：曲柄与摇杆支座距离为160mm,曲柄长度为80mm,搂膜连杆长度为140mm,摇杆长度为130mm,搂膜杆齿长度为420mm,机架与x轴正向夹角为16°,搂膜连杆与搂膜杆齿所夹锐角为260。对优化后的搂齿卸膜机构进行了运动学和动力学仿真,仿真结果表明机构满足卸膜要求。
7)制造了杆齿式残膜回收机的物理样机,通过田间试验证明,样机的作业质量满足技术要求。
With expand of the covering area and growth of age of plastic film, the residual plastic film left in fields caused serious pollution of the agriculture environment. Mechanical recycling plastic film can overcome shortcomings of the great labor intensity and low effective rate using artificial picking up. However the existing plastic film recycling equipments are generally design by experiences and have no precise theoretical researches for components, there are some issues including unreliable picking up performance and unloading film processes "back-carry" and serious wear of working parts. This paper researched deeply the key components of the pole-tooth residual film collecting machine by using theoretical analysis, the fuzzy optimization design, the virtual prototype simulation and experimental verification. Main research achievements include:
1) The experiment and analysis about the changes of the mechanical properties of residual film have been carried on. Compared with the0.012mm residual film, the longitudinal tensile load of the0.006mm residual film decreases37.59%, the transverse tensile load decreases38.68%, the right angle tear load decreases29.60%, the longitudinal tensile fracture elongation decreases20.35%, the transverse tensile fracture elongation decreases26.27%, the right angle tear fracture elongation decreases35.09%. The longitudinal and transverse tensile strength of0.012mm residual plastic films used90days (without weather resistant agent) reduced by at least40.43%, the smallest fracture elongation reduced by at least43.01%.
2) The deformation and stress distribution of the residual film and spring tooth were analyzed by nonlinear finite element method in the process of picking up film mulch. Using high speed camera system to test the deformation and stress distribution. Results show that the deformations of the film and spring tooth in the picked up process influence the residual film collecting rate of the spring-tooth, the deformations are related to the speed of the spring-tooth end and machine speed.
3) The influencing factors of the lifting film shovel's performance were researched in the paper. According to the working resistance model of the lifting film shovel, the strength and deformation of the shovel were analyzed by using the finite element method. The fuzzy comprehensive evaluation model of the lifting film shovel was established, the structure parameters and operating parameters were optimized by the experiment, the optimal entering soil angle of260and numbers of2bars of the lifting film shovel were gained.
4) The kinematics and dynamics analysis of slide-way spring-tooth collecting residual film mechanism were done, and the kinematics and dynamics models were established. The spring tooth end trajectory model was received by using the curve fitting of Matlab software, and the mathematical model of the slide-way was obtained according to the structural relationship, it provided the conditions for the digital processing of slide way profile.
5) By Multi-objective fuzzy optimization, the main structural parameters of the pick-up residual plastic film mechanism were identified:the slid-way minimum basic circle radius is55mm, the roller radius is15mm, the plate length is120mm, the pendulum length is70mm. Using ADM AS software, the kinematics and dynamics simulations of the fuzzy optimized collecting residual film mechanism were done, the results of simulation are consistent with the requirements of the picking up film. The working parameters were optimized by bench test of spring-tooth collecting residual film mechanism.
6) The movement analyses of the raking and unloading plastic film mechanism were done, and the mathematical models of the components' movement and stress were gained. According to the desired trajectory, the raking and unloading plastic film mechanism was optimized, and the parameters of parts were determined:the distance between crank and rocker is160mm, the crank length is80mm, the link length for scratching film is140mm, the rocker length is130mm, the tooth bar length is420mm, the angle between the frame and the x-axis positive direction is16°, the acute angle between the link length for scratching film and the tooth bar is26°.The kinematics and dynamics simulations of the optimized unloading residual film mechanism were done, the results of simulation are consistent with the requirements of the unloading film.
7) The pole tooth physical prototype of the residual film recycling machine was made, the field experiment has proved that the work qualities of the physical prototype meet the technical requirements.
引文
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