低功耗小型立轴式深耕机分段螺旋旋耕刀具的研制
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摘要
丘陵山地普遍使用微耕机进行耕地作业,长期浅耕带来了土壤板结、蓄水保墒能力下降等问题,亟需适应丘陵山地地形的小型深耕机进行深耕作业。为降低深耕作业刀具的功率消耗,该文研究了一种基于立式铣削、具有上翻下松作业特征的立轴式分段螺旋旋耕刀具,该刀具由立轴刀盘与沿其圆周方向均布的3把分段非连续螺旋型刀片组成。通过运动分析,建立了分段螺旋刀片运动参数模型,对刀片结构参数、刀具结构及工作参数进行了设计。基于光滑粒子流体动力学方法对设计的分段螺旋刀片作业过程中的土壤粒子运动、切削阻力及功率消耗等进行了分析,并试制样件进行了功率消耗及作业效果的实际测试。仿真结果表明:相对于传统立式直角旋耕刀片,分段螺旋刀片具有明显的上翻下松效果,切削阻力降低了37.5%,切削阻力波动范围平均值降低了60.6%,功率消耗降低了47.6%。土槽实测表明:设计的立轴式分段螺旋刀具实际功率消耗为2.86 kW,比仿真值高11.28%,两者比较接近,验证了仿真结果的有效性;同时,实际耕深稳定性达到设计要求且对土壤有较好的碎土和抛土能力。该研究可为低功耗小型深耕机的研发奠定基础。
Small deep-cultivators with light weight and simple structure are urgently needed to satisfy the requirements of deep cultivating in hilly regions. Development of a low power-consumption rotavator is a prerequisite for the lightweight of a small deep-cultivator. In this paper, in order to reduce the power consumption of the rotavator for a small vertical-shaft deep-cultivator, a multi-helical rotavator was proposed. The multi-helical rotavator consisted of a vertical-shaft rotavator head and 3 discontinuous multi-helical cutters that are unevenly distributed along the circumference of the head. The discontinuous multi-helical cutter consisted of a cutter-shaft and 3 discontinuous helical cutter edges that are evenly distributed along the axis of the cutter-shaft. The rotavator head had a diameter of 250 mm and the rotavator had a design tillage depth of 30 cm. The cutter-shaft length was 0.35 m and the helical angle of the helical cutter edge was 53o. Based on the motion analysis of the multi-helical rotavator, the motion path and its parameters model were established. The structure and operating parameters of the discontinuous multi-helical cutter and the rotavator were designed and analysed. Then the three-dimensional models of the discontinuous multi-helical cutter and the rotavator were established for simulation analysis. Based on the SPH(smoothed particle hydrodynamics) algorithm, the motion of soil particles, cutting resistance and power consumption were simulated and analysed during the operation of the discontinuous helical cutter and the traditional vertical-shaft orthogonal cutter in ANSYS LS-DYNA. In addition, an actual multi-helical rotavator was manufactured and its tillage effect and power consumption were tested. The simulation results showed that, comparing with the traditional vertical-shaft orthogonal cutter, the performance of the discontinuous helical cutter was significantly improved. 1) The discontinuous multi-helical cutter could greatly stir the upper soil particles, and the displacement of the upper soil particles was obviously increased during the cultivation process. At the same time, the lower soil particles were only slightly disturbed, and the displacement of the lower soil particles was significantly reduced. 2) The cutting resistance of the designed discontinuous helical cutter decreased by an average of 37.5%. Besides, the fluctuation range of cutting resistance decreased by an average of 60.6%, which could reduce the rotavator vibration and make the small deep-cultivator to work more stably and more reliable. 3) The total energy consumption of the designed discontinuous helical cutter was reduced by 58.7% and the average power consumption was reduced by 47.6%, which could reduce the weight of the small deep-cultivator under the same power consumption conditions. The test results showed that the actual power consumption of the designed multi-helical rotavator was 2.86 kW, which was 11.28% higher than the simulation value of 2.57 kW. The simulated power consumption value was close to the test value, which verifies the validity of the simulation results. At the same time, the average tillage depth of the designed multi-helical rotavator was 28.7 cm with a stability coefficient of 94.64% and the average soil pulverizing rate is 76.02%. Therefore, the designed multi-helical rotavator had better crushing and throwing ability than the traditional vertical-shaft orthogonal cutter, and could improve the soil subsoiling effect while meeting the requirement of the tillage depth. The reduction in cutting resistance and the decrease in cutting resistance fluctuation could also reduce the power consumption and vibration of small deep-cultivators.
Small deep-cultivators with light weight and simple structure are urgently needed to satisfy the requirements of deep cultivating in hilly regions. Development of a low power-consumption rotavator is a prerequisite for the lightweight of a small deep-cultivator. In this paper, in order to reduce the power consumption of the rotavator for a small vertical-shaft deep-cultivator, a multi-helical rotavator was proposed. The multi-helical rotavator consisted of a vertical-shaft rotavator head and 3 discontinuous multi-helical cutters that are unevenly distributed along the circumference of the head. The discontinuous multi-helical cutter consisted of a cutter-shaft and 3 discontinuous helical cutter edges that are evenly distributed along the axis of the cutter-shaft. The rotavator head had a diameter of 250 mm and the rotavator had a design tillage depth of 30 cm. The cutter-shaft length was 0.35 m and the helical angle of the helical cutter edge was 53o. Based on the motion analysis of the multi-helical rotavator, the motion path and its parameters model were established. The structure and operating parameters of the discontinuous multi-helical cutter and the rotavator were designed and analysed. Then the three-dimensional models of the discontinuous multi-helical cutter and the rotavator were established for simulation analysis. Based on the SPH(smoothed particle hydrodynamics) algorithm, the motion of soil particles, cutting resistance and power consumption were simulated and analysed during the operation of the discontinuous helical cutter and the traditional vertical-shaft orthogonal cutter in ANSYS LS-DYNA. In addition, an actual multi-helical rotavator was manufactured and its tillage effect and power consumption were tested. The simulation results showed that, comparing with the traditional vertical-shaft orthogonal cutter, the performance of the discontinuous helical cutter was significantly improved. 1) The discontinuous multi-helical cutter could greatly stir the upper soil particles, and the displacement of the upper soil particles was obviously increased during the cultivation process. At the same time, the lower soil particles were only slightly disturbed, and the displacement of the lower soil particles was significantly reduced. 2) The cutting resistance of the designed discontinuous helical cutter decreased by an average of 37.5%. Besides, the fluctuation range of cutting resistance decreased by an average of 60.6%, which could reduce the rotavator vibration and make the small deep-cultivator to work more stably and more reliable. 3) The total energy consumption of the designed discontinuous helical cutter was reduced by 58.7% and the average power consumption was reduced by 47.6%, which could reduce the weight of the small deep-cultivator under the same power consumption conditions. The test results showed that the actual power consumption of the designed multi-helical rotavator was 2.86 kW, which was 11.28% higher than the simulation value of 2.57 kW. The simulated power consumption value was close to the test value, which verifies the validity of the simulation results. At the same time, the average tillage depth of the designed multi-helical rotavator was 28.7 cm with a stability coefficient of 94.64% and the average soil pulverizing rate is 76.02%. Therefore, the designed multi-helical rotavator had better crushing and throwing ability than the traditional vertical-shaft orthogonal cutter, and could improve the soil subsoiling effect while meeting the requirement of the tillage depth. The reduction in cutting resistance and the decrease in cutting resistance fluctuation could also reduce the power consumption and vibration of small deep-cultivators.
引文
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[2]Matin M A,Fielke J M,Desbiolles J M A.Torque and energy characteristics for strip-tillage cultivation when cutting furrows using three designs of rotary blade[J]Biosystems Engineering,2015,129(1):329-340.
[3]杨冰.微耕机的结构设计与动力学研究[J].农业与技术,2017,37(12):81.Yang Bing.Structural design and dynamics of microtillers[J]Agriculture and Technology,2017,37(12):81.(in Chinese with English abstract)
[4]Zhang Fugui,Wei Wei,Wu Xuemei,et al.Design and simulation analysis of modal and harmonic response of chained deep-ploughing device[J].Proceedings of the 2017International Conference on Manufacturing Engineering and Intelligent materials(ICMEIM 2017),2017,100(1):296-308.
[5]Martinez J M,Galantini J A,Duval M E,et al.Tillage effects on labile pools of soil organic nitrogen in a semi-humid climate of Argentina:A long-term field study[J].Soil and Tillage Research,2017,169(1):71-80.
[6]Karmakar S,Kushwaha R L.Simulation of soil deformation around a tillage tool using computational fluid dynamics[J].American Society of Agricultural Engineers,2005,48(3):923-932.
[7]马俊艳,左强,王世梅,等.深耕及增施有机肥对设施菜地土壤肥力的影响[J].北方园艺,2011(24):186-190.Ma Junyan,Zuo Qiang,Wang Shimei,et al.Effects of deep tillage and organic fertilizer application on soil fertility in facility vegetable field[J].Northern Horticulture,2011(24):186-190.(in Chinese with English abstract)
[8]王秋菊,刘峰,焦峰,等.盐化草甸土和黑土型水田土壤连续深耕改土效果[J].农业工程学报,2017,33(22):152-158.Wang Qiuju,Liu Feng,Jiao Feng,et al.Effect on improving mollisol paddy soil and saline meadow soil by continuous deep ploughing[J].Transactions of the Chinese Society of Agricultural Engineering(Transactions of the CSAE),201733(22):152-158.(in Chinese with English abstract)
[9]濮超,刘鹏,阚正荣,等.耕作方式及秸秆还田对华北平原土壤全氮及其组分的影响[J].农业工程学报,2018,34(9):160-166.Pu Chao,Liu Peng,Kan Zhengrong,et al.Effects of tillage and straw mulching on soil total nitrogen and its components in north China plain[J].Transactions of the Chinese Society of Agricultural Engineering(Transactions of the CSAE),2018,34(9):160-166.(in Chinese with English abstract)
[10]谢迎新,靳海洋,孟庆阳,等.深耕改善砂姜黑土理化性状提高小麦产量[J].农业工程学报,2015,31(10):167-173.Xie Yingxin,Jin Haiyang,Meng Qingyang,et al.Deep tillage improving physical and chemical properties of soil and increasing grain yield of winter wheat in lime concretion black soil farmland[J].Transactions of the Chinese Society of Agricultural Engineering(Transactions of the CSAE),2015,31(10):167-173.(in Chinese with English abstract)
[11]Shahzad A,Xu Yueyue,Irshad A,et al.Tillage and deficit irrigation strategies to improve winter wheat production through regulating root development under simulated rainfall conditions[J].Agricultural Water Management,2018,209(1):44-54.
[12]Manuwa S I.Performance evaluation of tillage tines operating under different depths in a sandy clay loam soil[J].Soil and Tillage Research,2009,103(2):399-405.
[13]Godwin R J.A review of the effect of implement geometry on soil failure and implement forces[J].Soil and Tillage Research,2007,97(2):331-340.
[14]Dimitar K,Dimitrov,Mariyana I.Trends in organic farming development in bulgaria:Applying circular economy principles to sustainable rural development[J].Visegrad Journal on Bioeconomy and Sustainable Development,2017,6(1):10-16.
[15]丁为民,孙元昊,赵思琪,等.犁旋一体机自动调平系统设计与试验[J].农业工程学报,2018,34(17):25-31.Ding Weimin,Sun Yuanhao,Zhao Siqi,et al.Design and test of automatic leveling system of plough rotary machine[J].Transactions of the Chinese Society of Agricultural Engineering(Transactions of the CSAE),2018,34(17):25-31.(in Chinese with English abstract)
[16]郭俊,姬长英,方会敏,等.正反转旋耕后土壤和秸秆位移试验分析[J].农业机械学报,2016,47(5):21-26.Guo Jun,Ji Changying,Fang Huimin,et al.Experimental analysis of soil and straw displacement after up-cut and down-cut rotary tillage[J].Transactions of the Chinese Society for Agricultural Machinery,2016,47(5):21-26.(in Chinese with English abstract)
[17]熊平原,杨洲,孙志全,等.旋耕刀三向工作阻力试验及作业参数优化[J].农业工程学报,2017,33(19):51-58.Xiong Pingyuan,Yang Zhou,Sun Zhiquan,et al.Experiment on three-axis working resistances of rotary blade and working parameters optimization[J].Transactions of the Chinese Society of Agricultural Engineering(Transactions of the CSAE),2017,33(19):51-58.(in Chinese with English abstract)
[18]欧阳玉平,洪添胜,苏建,等.山地果园牵引式双轨运输机断绳制动装置设计与试验[J].农业工程学报,2014,30(18):22-29.Ouyang Yuping,Hong Tiansheng,Su Jian,et al.Design and experiment for rope brake device of mountain orchard traction double-track transporter[J].Transactions of the Chinese Society of Agricultural Engineering(Transactions of the CSAE),2014,30(18):22-29.(in Chinese with English abstract)
[19]李忠雨.自行式节能深耕机的研制[J].农业装备与车辆工程,2009(10):38-39.Li Zhongyu.Development of self-propelled energy-saving deep-tilling machine[J].Agricultural Equipment&Vehicle Engineering,2009(10):38-39.(in Chinese with English abstract)
[20]钟江,蒋建东,姜涛,等.基于光滑粒子流体动力学仿真的板结土壤深旋耕技术[J].机械工程学报,2010,46(19):63-69.Zhong Jiang,Jiang Jiandong,Jiang Tao,et al.Deep-tillage rotavator technology based on smoothed particle hydrodynamics simulation[J].Journal of Mechanical Engineering,2010,46(19):63-69.(in Chinese with English abstract)
[21]叶进,谢会川,杨仕,等.手扶式小型深耕机:201210078049X[P].2012-07-18.
[22]郭军义.一种立式旋耕机:2011200465458[P].2011-09-28.
[23]杨夫君.一种组合式ZENWF强力深松碎土机:2013202299004[P].2013-11-13.
[24]韩煜杰,李云伍,赵华慧,等.基于SPH算法的立式旋耕刀土壤切削仿真模拟[J].西南大学学报:自然科学版,2016,38(12):150-155.Han Yujie,Li Yunwu,Zhao Huahui,et al.Simulation of soil cutting by vertical rotary blade based on SPH method[J].Journal of Southwest University:Natural Science Edition,2016,38(12):150-155.(in Chinese with English abstract)
[25]Shrivastava A,Roland T,Berg H.The screw-like movement of a gliding bacterium is powered by spiral motion of cell-surface adhesins[J].Biophysical Journal,2016,111(5):1008-1013.
[26]Abichou M,Fournier C,Dornbusch T,et al.Parameterizing wheat leaf and tiller dynamics for faithful reconstruction of wheat plants by structural plant models[J].Field Crops Research,2018,218(1),213-230.
[27]李宝筏.农业机械学[M].北京:中国农业出版社,2003:9-33.
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