丘陵山地自走式玉米收获机设计方法与试验研究
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摘要
丘陵山地作为我国玉米的主要种植区,但其机收水平与平原地区相比,无论是规模还是速度,其差距都在进一步扩大。为此,本文以适用于丘陵山地的自走式玉米收获机为研究对象,基于田间适应性试验和室内试验台试验结果,分析了丘陵山地玉米收获机整机设计原则；基于玉米植株力学特性,研究了丘陵山地玉米收获机的设计方法；利用虚拟样机技术,对整机及摘穗部件进行了虚拟仿真分析；最终研制了适用于丘陵山地的玉米收获机,并进行了田间试验验证。本文的主要的研究工作如下：
(1)在查阅大量文献和深入调研的基础上,分析了当前国内外玉米收获机发展动态、关键技术和研究方法,总结了国内主要玉米收获机生产企业的机型参数,在此基础上,确定了本文的研究内容和技术路线。
(2)根据国内现有玉米收获机的分类和特点,提出了丘陵山地玉米收获机的筛选原则,筛选了两款小型玉米收获机,开展了丘陵山地玉米收获的适应性试验。基于试验结果,提出了目前国内玉米收获机在丘陵山地地区存在的问题和核心技术,为后续研究提供了数据支持。
(3)研制了玉米收获机室内多功能试验台,并进行了玉米植株喂入及摘穗过程试验。试验台包括玉米植株喂入试验装置、多工况摘穗和剥皮试验装置、功耗测试系统以及高速摄像系统。玉米植株喂入装置能够模拟玉米收获时植株喂入状态,同时能够实现喂入速度、行距及株距可调,并满足进行不对行收获的技术要求。多工况摘穗和剥皮试验装置利用变频调速电机调节拉茎辊与剥皮辊转速,同时能够方便快速调节拉茎辊、摘穗板间隙,摘穗倾角,剥皮辊间隙,压送器长度等参数。针对自走式玉米收获机摘穗装置,开展了不同工况下的功耗试验,并基于高速摄像技术,对摘穗和剥皮过程玉米穗的运动特征进行了分析。
(4)对丘陵山地某一种植品种的玉米植株物理几何参数进行了测量,获取了与机械化收获密切相关的植株几何参数,并建立了玉米植株关键几何参数的数学关联模型；基于试验和文献资料,研究了玉米茎秆的折弯、拉伸、剪切及挤压特性,获取了茎秆的最大折弯角、最大拉断力、最大剪切力和最大挤压破坏力；研究了苞叶和籽粒的力学特性,并获取了植株与不同材料的摩擦特性。
(5)基于丘陵山地地形地貌特点和轮式农业机械行走机理,进行了玉米收获机底盘设计方法研究,确定了整机物流模块、行走机构及传动机构的设计方案；基于玉米植株的物理力学特性,研究了玉米收获机关键部件设计方法。以玉米茎秆折弯、拉伸、剪切以及挤压特性,苞叶的拉伸特性以及籽粒的力学特性为基础,提出了分禾器、摘穗机构、秸秆粉碎机构的设计方法。
(6)基于虚拟样机技术和玉米植株在摘穗过程中的受力和运动分析,提出了玉米收获机关键部件仿真方法。以玉米植株的力学特性为基础,建立玉米茎秆及果穗的刚柔模型,确定了仿真关键参数取值,并进行玉米植株与关键部件相互作用的仿真分析。同时,进行了整机在不同坡度路面的爬坡及侧倾仿真试验。
(7)与企业合作研制了适用于丘陵山地的4YZP-2自走式玉米收获机。该机长度仅为3980mm,比国内2行收获机平均尺寸(5490mm)小27%；质量仅为1680kg,比国内2行收获机平均质量(2560kg)小34%同时,整机功率仅为22.98kW。通过田间试验,验证了该机在丘陵山地地区的适应性和工作可靠性。
Hilly regions are the main planting areas of com in China. However, the mechanized corn harvesting level in these areas is far lower than that in plain area in the respects of scale and rate. Considering this situation, this paper focuses on self-propelled corn harvester suitable for hilly regions. According to the results of adaptability tests and indoor test-bed experiments, the design principles of corn harvester machine were determined. Furthermore, the design method of self-propelled corn harvester was discussed based on the physical and mechanical properties of corn plant. Provided virtual prototyping technology, the vehicle and its snapping components were simulated. Finally, a self-propelled corn harvester for hilly regions was developed with field tests conducted.
(1) The development trend, key technology and research methods of corn harvester were investigated basing on literature review and in-depth survey. The model parameters of major domestic corn harvesting machine manufacturers were then summarized. From the above, the objectives and the technical route of this paper were determined.
(2) Through the classification and features of the existing domestic corn harvesters, we proposed the screening principle of corn harvester for hilly regions. Two small-scale corn harvesters were screened for adaptability test. From the results, the existing problems and key technologies of domestic corn harvesters in current situation were presented.
(3) The multifunction test-bed for corn harvester was developed for feed-in as well as snapping tests of corn plant. The test-bed consists of the plant-feed-in mechanism, the multi-condition snapping and peeling units, measurement system for power consumption, and high-speed camera system. The plant-feed-in mechanism can simulate the feed-in state during harvesting with adjustable feeding speed, row-spacing, and plant-spacing. Similarly, the rotating speeds of picking rolling and husking roller are adjustable by adopting a frequency conversion motor. Meanwhile, the snapping angle and the gaps of the stretching rollers, husking rollers and the snapping plate can be adjusted quickly and conveniently. The power consumption test was carried out and the motion characteristic parameters of corn stalk and ear were analyzed with the high-speed camera. The experimental data provides support for designing the snapping mechanism.
(4) Provided the measured physical dimensions of a certain type of hilly corn plant, a mathematical model of the corn plant associated with the key geometric parameters was formulated. On account of the experimental data and references, the bending, tensile, shear and compression properties of com stalk were studied. Consequently, we obtained the maximum values of the bending angle of corn stem, the tensile, shear, and extrusion failure forces of corn stalk. The mechanical properties of the grain bract and kernel were taken into consideration, and the friction characteristics between the plant and various materials were gained. The data describing the physical and mechanical properties of corn plant provides support for designing the snapping mechanism.
(5) The design method of harvester chassis was proposed considering the walking mechanism of wheeled agricultural machinery and hilly terrain features. Correspondingly we determined the design schemes of the whole logistics module, the walking and transmission mechanisms. The design method of the key components of corn harvester were then studied based on the mechanical properties of corn plants. Given the bending, tensile, shear and compression properties of corn stalk, the design approaches of the divider, snapping and straw chopper units were proposed.
(6) The simulation approach of key components for corn harvester was proposed in consideration of the analyses on force and kinematics during snapping process with application of virtual prototyping technology. The rigid-flexible model of corn stalk and ear were built on the mechanical properties of corn plant, which provides the key parameters used as simulation input. Then the interaction between the corn stalk and the machine key components, and the dynamic behaviors of the harvester traveling on various sloping grounds were simulated.
(7) A type of4YZP-2self-propelled corn harvester was developed in collaboration with an agricultural machinery manufacturer. It has a length of3980mm (27%less than the average length of domestic two-line harvesters) weighing1680kg (34%less than the average weight of domestic two-line harvesters) with a22.98kW engine power. Its adaptability and reliability were verified through field trials and it is proved to be applicable to hilly regions according to the results.
(1)在查阅大量文献和深入调研的基础上,分析了当前国内外玉米收获机发展动态、关键技术和研究方法,总结了国内主要玉米收获机生产企业的机型参数,在此基础上,确定了本文的研究内容和技术路线。
(2)根据国内现有玉米收获机的分类和特点,提出了丘陵山地玉米收获机的筛选原则,筛选了两款小型玉米收获机,开展了丘陵山地玉米收获的适应性试验。基于试验结果,提出了目前国内玉米收获机在丘陵山地地区存在的问题和核心技术,为后续研究提供了数据支持。
(3)研制了玉米收获机室内多功能试验台,并进行了玉米植株喂入及摘穗过程试验。试验台包括玉米植株喂入试验装置、多工况摘穗和剥皮试验装置、功耗测试系统以及高速摄像系统。玉米植株喂入装置能够模拟玉米收获时植株喂入状态,同时能够实现喂入速度、行距及株距可调,并满足进行不对行收获的技术要求。多工况摘穗和剥皮试验装置利用变频调速电机调节拉茎辊与剥皮辊转速,同时能够方便快速调节拉茎辊、摘穗板间隙,摘穗倾角,剥皮辊间隙,压送器长度等参数。针对自走式玉米收获机摘穗装置,开展了不同工况下的功耗试验,并基于高速摄像技术,对摘穗和剥皮过程玉米穗的运动特征进行了分析。
(4)对丘陵山地某一种植品种的玉米植株物理几何参数进行了测量,获取了与机械化收获密切相关的植株几何参数,并建立了玉米植株关键几何参数的数学关联模型；基于试验和文献资料,研究了玉米茎秆的折弯、拉伸、剪切及挤压特性,获取了茎秆的最大折弯角、最大拉断力、最大剪切力和最大挤压破坏力；研究了苞叶和籽粒的力学特性,并获取了植株与不同材料的摩擦特性。
(5)基于丘陵山地地形地貌特点和轮式农业机械行走机理,进行了玉米收获机底盘设计方法研究,确定了整机物流模块、行走机构及传动机构的设计方案；基于玉米植株的物理力学特性,研究了玉米收获机关键部件设计方法。以玉米茎秆折弯、拉伸、剪切以及挤压特性,苞叶的拉伸特性以及籽粒的力学特性为基础,提出了分禾器、摘穗机构、秸秆粉碎机构的设计方法。
(6)基于虚拟样机技术和玉米植株在摘穗过程中的受力和运动分析,提出了玉米收获机关键部件仿真方法。以玉米植株的力学特性为基础,建立玉米茎秆及果穗的刚柔模型,确定了仿真关键参数取值,并进行玉米植株与关键部件相互作用的仿真分析。同时,进行了整机在不同坡度路面的爬坡及侧倾仿真试验。
(7)与企业合作研制了适用于丘陵山地的4YZP-2自走式玉米收获机。该机长度仅为3980mm,比国内2行收获机平均尺寸(5490mm)小27%；质量仅为1680kg,比国内2行收获机平均质量(2560kg)小34%同时,整机功率仅为22.98kW。通过田间试验,验证了该机在丘陵山地地区的适应性和工作可靠性。
Hilly regions are the main planting areas of com in China. However, the mechanized corn harvesting level in these areas is far lower than that in plain area in the respects of scale and rate. Considering this situation, this paper focuses on self-propelled corn harvester suitable for hilly regions. According to the results of adaptability tests and indoor test-bed experiments, the design principles of corn harvester machine were determined. Furthermore, the design method of self-propelled corn harvester was discussed based on the physical and mechanical properties of corn plant. Provided virtual prototyping technology, the vehicle and its snapping components were simulated. Finally, a self-propelled corn harvester for hilly regions was developed with field tests conducted.
(1) The development trend, key technology and research methods of corn harvester were investigated basing on literature review and in-depth survey. The model parameters of major domestic corn harvesting machine manufacturers were then summarized. From the above, the objectives and the technical route of this paper were determined.
(2) Through the classification and features of the existing domestic corn harvesters, we proposed the screening principle of corn harvester for hilly regions. Two small-scale corn harvesters were screened for adaptability test. From the results, the existing problems and key technologies of domestic corn harvesters in current situation were presented.
(3) The multifunction test-bed for corn harvester was developed for feed-in as well as snapping tests of corn plant. The test-bed consists of the plant-feed-in mechanism, the multi-condition snapping and peeling units, measurement system for power consumption, and high-speed camera system. The plant-feed-in mechanism can simulate the feed-in state during harvesting with adjustable feeding speed, row-spacing, and plant-spacing. Similarly, the rotating speeds of picking rolling and husking roller are adjustable by adopting a frequency conversion motor. Meanwhile, the snapping angle and the gaps of the stretching rollers, husking rollers and the snapping plate can be adjusted quickly and conveniently. The power consumption test was carried out and the motion characteristic parameters of corn stalk and ear were analyzed with the high-speed camera. The experimental data provides support for designing the snapping mechanism.
(4) Provided the measured physical dimensions of a certain type of hilly corn plant, a mathematical model of the corn plant associated with the key geometric parameters was formulated. On account of the experimental data and references, the bending, tensile, shear and compression properties of com stalk were studied. Consequently, we obtained the maximum values of the bending angle of corn stem, the tensile, shear, and extrusion failure forces of corn stalk. The mechanical properties of the grain bract and kernel were taken into consideration, and the friction characteristics between the plant and various materials were gained. The data describing the physical and mechanical properties of corn plant provides support for designing the snapping mechanism.
(5) The design method of harvester chassis was proposed considering the walking mechanism of wheeled agricultural machinery and hilly terrain features. Correspondingly we determined the design schemes of the whole logistics module, the walking and transmission mechanisms. The design method of the key components of corn harvester were then studied based on the mechanical properties of corn plants. Given the bending, tensile, shear and compression properties of corn stalk, the design approaches of the divider, snapping and straw chopper units were proposed.
(6) The simulation approach of key components for corn harvester was proposed in consideration of the analyses on force and kinematics during snapping process with application of virtual prototyping technology. The rigid-flexible model of corn stalk and ear were built on the mechanical properties of corn plant, which provides the key parameters used as simulation input. Then the interaction between the corn stalk and the machine key components, and the dynamic behaviors of the harvester traveling on various sloping grounds were simulated.
(7) A type of4YZP-2self-propelled corn harvester was developed in collaboration with an agricultural machinery manufacturer. It has a length of3980mm (27%less than the average length of domestic two-line harvesters) weighing1680kg (34%less than the average weight of domestic two-line harvesters) with a22.98kW engine power. Its adaptability and reliability were verified through field trials and it is proved to be applicable to hilly regions according to the results.
引文
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