风筛式清选装置设计理论与方法研究
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摘要
在农作物生产中,农业物料的清选是一项重要内容。现代联合收割机中常用风筛式平面振动筛进行清选,而风筛式平面振动筛筛分过程是一个极为复杂的随机过程,随着物理实验技术的发展及计算机技术的进步,运用现代设计理论与方法对风筛式清选装置进行系统地分析与研究的成为一个研究热点,因此,本文以稻谷清选为研究对象,开展风筛式清选装置设计理论与方法的研究,主要内容如下。
1、测量了4LZ-1.0型联合收割机排出物的组成,测量结果表明,该机型清选损失率小于1%,但排出物中,谷粒与瘪谷没能有效地分离。对排出物中谷粒、瘪谷及茎秆的三维尺寸、密度、刚度及剪切强度等物性参数进行了测量,同时对三者之间相互作用的物性参数,如恢复系数、摩擦系数等进行了测量。
2、对风筛式清装置进行了总体设计,对其振动筛总成进行了三维设计,运用三维分析软件,对筛面进行了运动学分析,并对筛面上点的运动进行了曲线拟合,分析表明,筛面上的点作周期性运动,运动曲线可用正弦函数表达。同时,运用ADAMS,分析了清选装置主要参数变化对筛面加速度的影响,并对主要参数进行了优化,优化结果表明,曲柄转速及半径对筛面的加速度影响敏感,其中曲柄转速n=360r/min、曲柄半径r=2.5cm时,有利于筛面上谷物的筛分。
3、基于气固两相流体力学理论,分析了谷粒在筛面气流场的受力情况；运用Pro/E软件建立了风筛式清选装置三维几何模型,将其划分为结构化四面体网格,在恒压力边界下,利用CFD软件中的标准k-ε流模型和壁面函数法对清选装置内气流场进行了数值模拟。分析结果表明：风扇的外端风速最大,在风道与风扇滚筒的交界处,气流做离心运动,气流沿风扇叶片的切线方向吹出,形成比较流畅的气流场,在鱼鳞筛网处气流的大小方向发生改变,鱼鳞开口处速度聚集,气流从筛孔吹出,向着宜于将杂物吹出的方向流出。由于鱼鳞开口的影响,在筛面上方,离筛面较近处气流速度较大,分析表明,在保证清选效率的情况下,可以缩短清选装置的竖向距离。数值模拟同时表明,气流速度在壁面发生一定的冲击现象,压强存在明显梯度。通过正交实验对筛面气流场进行了优化,优化结果表明,离心风机转速为700r/min,离心风机倾角为25°,鱼鳞筛夹角20°时,有利于降低含杂率及损失率。
4、利用逆向工程理论,对稻谷谷粒、瘪谷、短茎秆进行了三维模型重构。运用三维离散元形状模型理论,采用粘接法,构造了稻谷谷粒、瘪谷及短茎秆的三维离散元模型。该模型与实际模型形状尺寸及密度值误差在5%以内,可成为稻谷收获清选动力学及运动学分析运动的力学基础。
5、对稻谷的脱出混合物在平面振动筛上的清选行为进行了系统的三维离散元数值模拟研究。通过数值模拟,再现了颗粒流在筛面激励下的分层及透筛过程,并分析了颗粒流的运动规律。研究了各振动参数对谷粒及瘪谷在筛面运动的影响,并通过曲线拟合得到其回归方程,探索了颗粒流在筛面上的分层及透筛机理。
6、运用三维离散元分析模拟理论,对平面振动筛的筛分效率进行了系统的研究。引入动态筛分效率的概念,分析了在筛分过程中,筛面的振动频率、振幅及筛面倾角对筛分效率的影响。在此基础上,进行了正交仿真实验,得到了最佳筛分效率时的振动参数,即振动频率5Hz、振幅25mm、倾角为4°。同时建立了筛分效率的多元非线性模型,该模型丰富了颗粒物料的振动筛分理论,为传统筛分机的优化设计和新型筛分装置的研制提供了理论依据。
7、运用实验的方法,对数值模拟进行了验证。运用高速图像处理系统,在实验台上进行了筛分过程的运动示踪,将离散元仿真结果与实验结果进行对比,分析表明,两种情况下,颗粒运动趋势相近；通过对实验时筛下物的统计,得到了筛分效率沿筛面分布规律,筛分效率在筛面上呈正态分布,筛面中前部筛分效率最高,该规律与离散元模拟结果规律基本一致；运用风速仪,对不同风机转速及不同风机倾角下筛面中点及出风口速度进行了测量,并与CFD模拟结果进行对比分析,分析表明,模拟结果与实验结果变化趋势相似,运用CFD进行气流场分析完全可行。
During the crop planting, the cleaning of agricultural materials plays an important role. The air-and-screen flat cleaning vibrating screen has been commonly used in modern combine, however, the air-and-screen flat shaker screening process is a very complex random process. With the development of physical testing technology and computer technology, many specialists focus on using modern design theory and methods for system analysis and research of air-and-screen cleaning device, therefore, concerning to the selecting of rice, the air-and-screen cleaning device was systematically studied. The main contents included.
1. The composition of4LZ1.0type combine effluent was measured. Analysis showed that the loss was smaller for using this type of machine, however, Grain and immature grain was not effectively isolated in the effluent. The three-dimensional size, density, stiffness and shear strength and other physical parameters of grain and immature grain were measured, at the same time, the interaction between the three physical parameters, such as the restitution coefficient, friction coefficient was measured, too.
2. Air-and-screen cleaning device was designed, and the shaker assembly was carried by three-dimensional reconstruction and we used kinematics analysis tools for curve fitting for movement of points which were on the screen surface. Analysis showed that the points on the surface of screen did periodic motion; the motion curve can be expressed by the sine function. Meanwhile, the influence for changing cleaning device size to the surface acceleration was analyzed by ADMAS, and the sizes are optimized. Optimization results showed that crank speed and the radius had sensitive influence to the acceleration on the surface of the screen. The acceleration of the points on the surface of screen is the best when crank rotation speed n=360r/min and crank radius r=2.5cm.
3. Based on the gas-solid phase fluid mechanics theory, the force of the grain in the screen surface was analyzed.3D models were established by the Gambit software and divided into structured tetrahedron grid. In the constant pressure boundary, the cleaning device was numerical simulation through the standard k-s turbulent model of the CFD software and wall function method. Analysis showed that the biggest wind speed was out of the fan, in the boundary of the duct and fan cylinder, the air did centrifugal motion, and air blow out along the tangent of the fan blades and formed a smooth flow whose size and direction was changed in the scale sieve net. In the scale sieve net openings, the speed gathered and air blow out from the screen which was good for blowing out debris flow. Due to the influence of the scales openings, in the screen surface above, the face of the recent screen surface was with bigger air velocity. The analysis showed that in the guarantee of cleaning and choosing efficiency, the vertical distance of the cleaning device could be shortened. Numerical simulation also indicated that the airflow velocity in the wall had certain impact phenomenon, there exists significant pressure gradient. Through the orthogonal experiments, the screen surface wind field was optimized, and the optimization results showed that, centrifugal fan speed for700RPM, centrifugal fan angle of25degrees and the scales screen angle20degrees were helpful to reduce the impurity rate and loss.
4. Based on reverse engineering theory, the three-dimensional models of rice grain and flat valley were reconstructed. With the idea of three-dimensional discrete element shape model theory, the3D models of rice grain, immature rice and short stem were established using bonding method. The error between this model and actual one was less than5%in shape, size and density values. In other words, this model could be the dynamics, kinematics and mechanics basis of grain screening analyses.
5. The3D discrete element numerical simulation research was conducted, focusing on screening behavior of rice emergence mixture on the vibrating screen. Through numerical simulation, the layering and screening progresses of particle flow were represented with the excitation of the screen plane. The movement principles of particle flow were analyzed as well as the influence from each parameter on the grain and immature rice movement on the screen. At the same time, the regression equation was formed by curving fitting so as to explore the layering and screening mechanism of particle flow on the screen plane.
6. The study on screening efficiency of plane vibrating screen was conducted systematically based on the3D discrete element analysis simulation theory. The concept of dynamic screening efficiency was introduced in order to analyze the disciplines of vibration frequency, amplitude and screen inclination which influenced screening efficiency during the screening progress. On the basis, we conducted an orthogonal simulation experiment to obtain the parameters of the best screening efficiency, namely vibration frequency for5Hz, amplitude for25mm and dip angle for4degree. Meanwhile, multiple elemental nonlinear model of screening efficiency was established to enrich particle vibrating and screening theory. In addition, the model provided theoretical basis for optimization design of traditional screen machine and new cleaning device research.
7. The simulation of numerical value was verified by series of experiments. Using high-speed image processing system, the movement tracer of the screening process was conducted on the test-bed, the analysis of the results obtained from Discrete Element simulation and experiment showed that the move tendency of the particle obtained from the two different measures were basically the same; Through the statistics of the tested things under the screen, the regularity of distribution of the screening efficiency along the screen surface was obtained, screening efficiency on the screen belongs to normal distribution, the screening efficiency of the front screen is the highest, which is in accordance with the law obtained from the discrete element simulation. The air speed of the sieve halfway point and the outlet were measured with anemometer under the condition of different fan speed and fan angle, then, the compared analysis of the result and the simulation result of CFD was formed, which showed the change of simulation results and experimental results were basically identical, so using CFD on the wind field analysis is feasible.
1、测量了4LZ-1.0型联合收割机排出物的组成,测量结果表明,该机型清选损失率小于1%,但排出物中,谷粒与瘪谷没能有效地分离。对排出物中谷粒、瘪谷及茎秆的三维尺寸、密度、刚度及剪切强度等物性参数进行了测量,同时对三者之间相互作用的物性参数,如恢复系数、摩擦系数等进行了测量。
2、对风筛式清装置进行了总体设计,对其振动筛总成进行了三维设计,运用三维分析软件,对筛面进行了运动学分析,并对筛面上点的运动进行了曲线拟合,分析表明,筛面上的点作周期性运动,运动曲线可用正弦函数表达。同时,运用ADAMS,分析了清选装置主要参数变化对筛面加速度的影响,并对主要参数进行了优化,优化结果表明,曲柄转速及半径对筛面的加速度影响敏感,其中曲柄转速n=360r/min、曲柄半径r=2.5cm时,有利于筛面上谷物的筛分。
3、基于气固两相流体力学理论,分析了谷粒在筛面气流场的受力情况；运用Pro/E软件建立了风筛式清选装置三维几何模型,将其划分为结构化四面体网格,在恒压力边界下,利用CFD软件中的标准k-ε流模型和壁面函数法对清选装置内气流场进行了数值模拟。分析结果表明：风扇的外端风速最大,在风道与风扇滚筒的交界处,气流做离心运动,气流沿风扇叶片的切线方向吹出,形成比较流畅的气流场,在鱼鳞筛网处气流的大小方向发生改变,鱼鳞开口处速度聚集,气流从筛孔吹出,向着宜于将杂物吹出的方向流出。由于鱼鳞开口的影响,在筛面上方,离筛面较近处气流速度较大,分析表明,在保证清选效率的情况下,可以缩短清选装置的竖向距离。数值模拟同时表明,气流速度在壁面发生一定的冲击现象,压强存在明显梯度。通过正交实验对筛面气流场进行了优化,优化结果表明,离心风机转速为700r/min,离心风机倾角为25°,鱼鳞筛夹角20°时,有利于降低含杂率及损失率。
4、利用逆向工程理论,对稻谷谷粒、瘪谷、短茎秆进行了三维模型重构。运用三维离散元形状模型理论,采用粘接法,构造了稻谷谷粒、瘪谷及短茎秆的三维离散元模型。该模型与实际模型形状尺寸及密度值误差在5%以内,可成为稻谷收获清选动力学及运动学分析运动的力学基础。
5、对稻谷的脱出混合物在平面振动筛上的清选行为进行了系统的三维离散元数值模拟研究。通过数值模拟,再现了颗粒流在筛面激励下的分层及透筛过程,并分析了颗粒流的运动规律。研究了各振动参数对谷粒及瘪谷在筛面运动的影响,并通过曲线拟合得到其回归方程,探索了颗粒流在筛面上的分层及透筛机理。
6、运用三维离散元分析模拟理论,对平面振动筛的筛分效率进行了系统的研究。引入动态筛分效率的概念,分析了在筛分过程中,筛面的振动频率、振幅及筛面倾角对筛分效率的影响。在此基础上,进行了正交仿真实验,得到了最佳筛分效率时的振动参数,即振动频率5Hz、振幅25mm、倾角为4°。同时建立了筛分效率的多元非线性模型,该模型丰富了颗粒物料的振动筛分理论,为传统筛分机的优化设计和新型筛分装置的研制提供了理论依据。
7、运用实验的方法,对数值模拟进行了验证。运用高速图像处理系统,在实验台上进行了筛分过程的运动示踪,将离散元仿真结果与实验结果进行对比,分析表明,两种情况下,颗粒运动趋势相近；通过对实验时筛下物的统计,得到了筛分效率沿筛面分布规律,筛分效率在筛面上呈正态分布,筛面中前部筛分效率最高,该规律与离散元模拟结果规律基本一致；运用风速仪,对不同风机转速及不同风机倾角下筛面中点及出风口速度进行了测量,并与CFD模拟结果进行对比分析,分析表明,模拟结果与实验结果变化趋势相似,运用CFD进行气流场分析完全可行。
During the crop planting, the cleaning of agricultural materials plays an important role. The air-and-screen flat cleaning vibrating screen has been commonly used in modern combine, however, the air-and-screen flat shaker screening process is a very complex random process. With the development of physical testing technology and computer technology, many specialists focus on using modern design theory and methods for system analysis and research of air-and-screen cleaning device, therefore, concerning to the selecting of rice, the air-and-screen cleaning device was systematically studied. The main contents included.
1. The composition of4LZ1.0type combine effluent was measured. Analysis showed that the loss was smaller for using this type of machine, however, Grain and immature grain was not effectively isolated in the effluent. The three-dimensional size, density, stiffness and shear strength and other physical parameters of grain and immature grain were measured, at the same time, the interaction between the three physical parameters, such as the restitution coefficient, friction coefficient was measured, too.
2. Air-and-screen cleaning device was designed, and the shaker assembly was carried by three-dimensional reconstruction and we used kinematics analysis tools for curve fitting for movement of points which were on the screen surface. Analysis showed that the points on the surface of screen did periodic motion; the motion curve can be expressed by the sine function. Meanwhile, the influence for changing cleaning device size to the surface acceleration was analyzed by ADMAS, and the sizes are optimized. Optimization results showed that crank speed and the radius had sensitive influence to the acceleration on the surface of the screen. The acceleration of the points on the surface of screen is the best when crank rotation speed n=360r/min and crank radius r=2.5cm.
3. Based on the gas-solid phase fluid mechanics theory, the force of the grain in the screen surface was analyzed.3D models were established by the Gambit software and divided into structured tetrahedron grid. In the constant pressure boundary, the cleaning device was numerical simulation through the standard k-s turbulent model of the CFD software and wall function method. Analysis showed that the biggest wind speed was out of the fan, in the boundary of the duct and fan cylinder, the air did centrifugal motion, and air blow out along the tangent of the fan blades and formed a smooth flow whose size and direction was changed in the scale sieve net. In the scale sieve net openings, the speed gathered and air blow out from the screen which was good for blowing out debris flow. Due to the influence of the scales openings, in the screen surface above, the face of the recent screen surface was with bigger air velocity. The analysis showed that in the guarantee of cleaning and choosing efficiency, the vertical distance of the cleaning device could be shortened. Numerical simulation also indicated that the airflow velocity in the wall had certain impact phenomenon, there exists significant pressure gradient. Through the orthogonal experiments, the screen surface wind field was optimized, and the optimization results showed that, centrifugal fan speed for700RPM, centrifugal fan angle of25degrees and the scales screen angle20degrees were helpful to reduce the impurity rate and loss.
4. Based on reverse engineering theory, the three-dimensional models of rice grain and flat valley were reconstructed. With the idea of three-dimensional discrete element shape model theory, the3D models of rice grain, immature rice and short stem were established using bonding method. The error between this model and actual one was less than5%in shape, size and density values. In other words, this model could be the dynamics, kinematics and mechanics basis of grain screening analyses.
5. The3D discrete element numerical simulation research was conducted, focusing on screening behavior of rice emergence mixture on the vibrating screen. Through numerical simulation, the layering and screening progresses of particle flow were represented with the excitation of the screen plane. The movement principles of particle flow were analyzed as well as the influence from each parameter on the grain and immature rice movement on the screen. At the same time, the regression equation was formed by curving fitting so as to explore the layering and screening mechanism of particle flow on the screen plane.
6. The study on screening efficiency of plane vibrating screen was conducted systematically based on the3D discrete element analysis simulation theory. The concept of dynamic screening efficiency was introduced in order to analyze the disciplines of vibration frequency, amplitude and screen inclination which influenced screening efficiency during the screening progress. On the basis, we conducted an orthogonal simulation experiment to obtain the parameters of the best screening efficiency, namely vibration frequency for5Hz, amplitude for25mm and dip angle for4degree. Meanwhile, multiple elemental nonlinear model of screening efficiency was established to enrich particle vibrating and screening theory. In addition, the model provided theoretical basis for optimization design of traditional screen machine and new cleaning device research.
7. The simulation of numerical value was verified by series of experiments. Using high-speed image processing system, the movement tracer of the screening process was conducted on the test-bed, the analysis of the results obtained from Discrete Element simulation and experiment showed that the move tendency of the particle obtained from the two different measures were basically the same; Through the statistics of the tested things under the screen, the regularity of distribution of the screening efficiency along the screen surface was obtained, screening efficiency on the screen belongs to normal distribution, the screening efficiency of the front screen is the highest, which is in accordance with the law obtained from the discrete element simulation. The air speed of the sieve halfway point and the outlet were measured with anemometer under the condition of different fan speed and fan angle, then, the compared analysis of the result and the simulation result of CFD was formed, which showed the change of simulation results and experimental results were basically identical, so using CFD on the wind field analysis is feasible.
引文
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