自走式方草捆压捆机关键部件优化设计与试验研究
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摘要
针对我国北方早作区等山区、丘陵小地块牧草种植区配套收获机械短缺的问题,该文提出了适合小地块收获的牧草捡拾压捆作业工艺及整机结构方案,设计了适合小地块作业的自走式方草捆压捆机。利用拓扑优化设计理论对整机机架材料布局进行了优化设计；创新性设计了一种带有十字套结构的燕尾形滑道压缩机构,并对压缩机构进行了可靠性分析：设计了适用于该机的L型拨叉,进行了不同拨叉作业效果的对比试验。完成了整机的田间性能试验,试验结果表明整机作业质量与机器性能满足设计要求。
主要研究成果包括：
(1)针对小地块牧草收获,提出了牧草捡拾压捆作业工艺及整机结构方案；进行了自走式方草捆压捆机的总体设计,具体包括整机设计原则、作业工艺和结构方案的制定,传动系统和液压系统的设计,捡拾机构、螺旋扒指式输送器和链耙式输送器等部件的结构设计和参数分析；完成了整机试制。
(2)运用拓扑优化方法,进行了整机机架的优化设计,基于拓扑分析结果,进行了机架的合理造型。对优化后的机架进行了静力学分析和模态分析,结果表明应力和变形均满足设计要求,机架的低阶固有频率分布均匀,符合动态特性要求。
(3)针对压缩机构的可靠性问题,创新设计了一种带有十字套结构的燕尾形滑道压缩机构；在压缩力最大的工况下,对活塞进行了结构分析；建立了连杆和曲柄的应力疲劳分析模型,通过计算,得出了疲劳寿命和安全系数分布,以及疲劳寿命与施加载荷的敏感度曲线,为后续的优化提供了理论依据。
(4)通过设定拨叉运动姿态,设计出三种拨叉,即L型拨叉、宽型拨叉和窄型拨叉,对三种拨叉的拨草机理进行了分析与讨论。重点对L型拨叉工作面造型进行了分析,并进行了运动学仿真,对其运动姿态、速度和轨迹进行了研究；运用响应面方法,对L型拨叉进行了形状优化。最后以规则草捆率为评价指标,对三种拨叉进行了试验研究,结果表明L型拨叉能够更高效地完成拨草作业。
(5)进行了整机的田间性能试验。试验结果表明：草捆密度、规则草捆率、抗摔率、成捆率和损失率等都达到了设计要求；整机协调性好,运移灵活,爬坡性好,实现了无级调速,机器性能指标达到设计要求。
To solve the harvester shortage problem in the pasture cultivation areas, especially brae and hilly terrain of northern china, a kind of pasture pick-up baler operation process and its whole structure scheme were proposed. And the small self-propelled rectangular baler was designed for small plot operation. The material arrangement for whole frame was optimized by using the topology optimization design theory. A kind of dovetail slide compression mechanism with cross sleeve structure was designed, and the reliability evaluation of compression mechanism was analyzed. An1type feeding fork was designed based on the motion attitude; meanwhile some experiments were done for comparing different feeding forks shape. Field performance tests were conducted, the machine and operating showed good performance.
The main results as bellow:
(1) The design scheme of small self-propelled rectangular baler was proposed for small plots of pasture harvesting.Completed the the overall design, the main contents were as follows:the overall design principle, press process technical study of self-propelled rectangular baler, the whole scheme design, the composition and working principles of transmission system, and analysis of the structure and parameters on hydraulic, pick-up system, screw mechanism and chain scraper conveyor, the trial of the baler.
(2) The method of topology optimization was used to optimize the frame. According to the results, the model was restored, and then the topological shape was designed reasonable. The restored frame was analyzed by using statics method and modal method. The stress and deformation were meeting the design requirements, and the lower order natural frequency of frame was evenly distributed.
(3) Aim at the reliability of the compression mechanism, a new kind of dovetail slide compression mechanism which have cross sleeve structure was designed innovationly. Based on this mechanism, the load on the connecting rod and crank was analyzed, and then the model based on stress and fatigue analysis was built. The fatigue life and distribution of safety factor of connecting rod and crank were calculated, and the fatigue life and the load sensitivity curve, provided reference for subsequent optimization.
(4) Based on the motion attitude, three kinds of feeding forks which include a wide type feeding fork, a narrow feeding fork and an L type feeding fork were designed. Then, analyzed and discussed the mechanism of three forks sending pasture.
Emphases on L-shaped fork, analysed the Working surface shape.And the kinematics simulation of the L-shaped fork was studied in ADAMS software, including sports attitude, speed, and trajectory. Using response surface method, optimize the L-type fork's shape. Finally, some experiments were done for comparing the three kinds of feeding forks shape and the evaluation is rule bale rate. The results showed that:L-type fork have more efficient on completing the reversal of grass bale job link.
(5) Conducted a field experiment on the prototype. The test results showed that:alfalfa bale density, rules bundles rate, bundle rate drop rate and loss rate have reached the design requirements; t the machine is well in coordination, flexible migration is,climbing and has achieved a variable speed adjust; and the performance indicators have met the design requirements.
主要研究成果包括：
(1)针对小地块牧草收获,提出了牧草捡拾压捆作业工艺及整机结构方案；进行了自走式方草捆压捆机的总体设计,具体包括整机设计原则、作业工艺和结构方案的制定,传动系统和液压系统的设计,捡拾机构、螺旋扒指式输送器和链耙式输送器等部件的结构设计和参数分析；完成了整机试制。
(2)运用拓扑优化方法,进行了整机机架的优化设计,基于拓扑分析结果,进行了机架的合理造型。对优化后的机架进行了静力学分析和模态分析,结果表明应力和变形均满足设计要求,机架的低阶固有频率分布均匀,符合动态特性要求。
(3)针对压缩机构的可靠性问题,创新设计了一种带有十字套结构的燕尾形滑道压缩机构；在压缩力最大的工况下,对活塞进行了结构分析；建立了连杆和曲柄的应力疲劳分析模型,通过计算,得出了疲劳寿命和安全系数分布,以及疲劳寿命与施加载荷的敏感度曲线,为后续的优化提供了理论依据。
(4)通过设定拨叉运动姿态,设计出三种拨叉,即L型拨叉、宽型拨叉和窄型拨叉,对三种拨叉的拨草机理进行了分析与讨论。重点对L型拨叉工作面造型进行了分析,并进行了运动学仿真,对其运动姿态、速度和轨迹进行了研究；运用响应面方法,对L型拨叉进行了形状优化。最后以规则草捆率为评价指标,对三种拨叉进行了试验研究,结果表明L型拨叉能够更高效地完成拨草作业。
(5)进行了整机的田间性能试验。试验结果表明：草捆密度、规则草捆率、抗摔率、成捆率和损失率等都达到了设计要求；整机协调性好,运移灵活,爬坡性好,实现了无级调速,机器性能指标达到设计要求。
To solve the harvester shortage problem in the pasture cultivation areas, especially brae and hilly terrain of northern china, a kind of pasture pick-up baler operation process and its whole structure scheme were proposed. And the small self-propelled rectangular baler was designed for small plot operation. The material arrangement for whole frame was optimized by using the topology optimization design theory. A kind of dovetail slide compression mechanism with cross sleeve structure was designed, and the reliability evaluation of compression mechanism was analyzed. An1type feeding fork was designed based on the motion attitude; meanwhile some experiments were done for comparing different feeding forks shape. Field performance tests were conducted, the machine and operating showed good performance.
The main results as bellow:
(1) The design scheme of small self-propelled rectangular baler was proposed for small plots of pasture harvesting.Completed the the overall design, the main contents were as follows:the overall design principle, press process technical study of self-propelled rectangular baler, the whole scheme design, the composition and working principles of transmission system, and analysis of the structure and parameters on hydraulic, pick-up system, screw mechanism and chain scraper conveyor, the trial of the baler.
(2) The method of topology optimization was used to optimize the frame. According to the results, the model was restored, and then the topological shape was designed reasonable. The restored frame was analyzed by using statics method and modal method. The stress and deformation were meeting the design requirements, and the lower order natural frequency of frame was evenly distributed.
(3) Aim at the reliability of the compression mechanism, a new kind of dovetail slide compression mechanism which have cross sleeve structure was designed innovationly. Based on this mechanism, the load on the connecting rod and crank was analyzed, and then the model based on stress and fatigue analysis was built. The fatigue life and distribution of safety factor of connecting rod and crank were calculated, and the fatigue life and the load sensitivity curve, provided reference for subsequent optimization.
(4) Based on the motion attitude, three kinds of feeding forks which include a wide type feeding fork, a narrow feeding fork and an L type feeding fork were designed. Then, analyzed and discussed the mechanism of three forks sending pasture.
Emphases on L-shaped fork, analysed the Working surface shape.And the kinematics simulation of the L-shaped fork was studied in ADAMS software, including sports attitude, speed, and trajectory. Using response surface method, optimize the L-type fork's shape. Finally, some experiments were done for comparing the three kinds of feeding forks shape and the evaluation is rule bale rate. The results showed that:L-type fork have more efficient on completing the reversal of grass bale job link.
(5) Conducted a field experiment on the prototype. The test results showed that:alfalfa bale density, rules bundles rate, bundle rate drop rate and loss rate have reached the design requirements; t the machine is well in coordination, flexible migration is,climbing and has achieved a variable speed adjust; and the performance indicators have met the design requirements.
引文
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