玉米秸秆青贮工艺研究及打捆包膜机设计
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摘要
玉米秸秆打捆包膜机是一个典型的机电一体化设备,它能将粉碎的玉米秸秆进行收集、传送和打捆,最后用塑料薄膜包好贮藏起来。为了提高玉米秸秆的青贮品质,在查阅了国内外大量文献基础上,本文对玉米秸秆青贮工艺做了深入、细致地研究,总结出湿度、温度、捆包的密实度、包膜的材料及层数等是保证青贮品质的关键因素。本着先进实用、设备为青贮工艺服务的原则,在大量试验基础上得到优化的捆包参数,研制了一种新型玉米秸秆圆捆打捆包膜机,实现了低成本、高效率、高质量的打捆包膜自动一体化。
文章首先分析了青贮作物的原理、青贮条件及青贮工艺过程,经对比研究,选择了玉米秸秆圆捆青贮方法;其次通过参考国内外大量文献并多次试验研究出了捆包设计参数对青贮品质的影响并得到了捆包青贮的优化参数;再次,针对青贮参数,建立了捆包模型,并以此设计了打捆包膜机整机的机械结构。上料单元采用了可折叠料斗和刮板链轮机构、打捆单元采用打捆钢辊配合电动推杆机构,包膜单元将塑料膜和旋转支架作为其主要组成部分,同时采用大马力拖拉机作为整机的牵引设备;最后,重点阐述了打捆包膜机的控制单元进行设计过程。本单元能够通过对捆包转速、密实度和包膜层数等可控参数的调整,满足青贮工艺要求。控制单元的硬件采用西门子S7-200 PLC作为控制器,执行元件采用交、直流电机,通过对变频器的控制实现速度的调节,通过多种传感器实现位置检测、速度检测、压力等检测和控制;控制单元的软件采用STEP 7作为PLC的开发编程工具,该软件主要通过梯形图语言编写程序,也可以转换成STL语言同步编写。同时采用WINCC作为监控软件主要实现系统的管理及控制功能,采用EB8000作为HMI的程序界面,方便了工作人员手动操作。PC与PLC之间采用RS232通讯,PLC与HMI之间采用RS485通信,PC与HMI之间则采用USB线直接下载界面,实现了整机控制系统连续自动化操作。
选取粉碎玉米秸秆进行打捆包膜试验,结果表明:该样机能够对打捆包膜参数实时调整,实现玉米秸秆打捆包膜的自动化连续工作,且工作效率高、捆包成形较好、成品质量稳定。经过后期的贮藏,其青贮效果比其他贮藏方式效果有明显改善。
Baling and wrapping machine of maize is a typical mechatronics device. This device can convey the crush corn stalks and bale it with thread, then bag it with plastic film and be stored. With national situation of China as its goal, the technology of corn straw silage has been developed refering to abundant documents, Silage quality parameters are got after lots of experiments .According to these parameters, a new mechatronics device are developed, and the goals of low-cost, high efficiency and high quality automation integrate are achieved.
Firstly, the principle, conditions and the process of ensiling technology of ensiling crops have been analyzed. The method of baling and wrapping of maize which is the most appropriate method is choosed after comparing a variety of ensiling method. Secondly, the effective factors of bundles to the quality of ensiling and reasonable parameters of bale ensiling have been gotten .by referring to a large number of domestic and foreign documents and testing many times. Thirdly, a model of bundles was established for ensiling parameter and the mechanical structure was modeled. In order to guaranting efficiency and quality principles, a folding hopper and scraping board sprocket as material institutions was designed, and Bundling steel roller suit electric putting as playing bundle cabin and plastic film and rotating bracket as the main part of the package film unit , while used the large horsepower tractor as the driven device. Finally, a control system for the bundling coating machine was developed according to the mechanical structure, which can meet the ensiling process requirements by adjusting baling speed, density and coating layer. A Siemens S7-200 PLC was choosed as controller in the hardware of controlling unit, and AC and DC motors are choosed as actuators. Speed regulation is achieved by Frequency converters’control .the location, velocity and pressure are detected by sensors.The software of STEP 7 is choosed as PLC programming tool, which can write ladder diagram and STL language. System of management and control functions are achieved by WINCC . EB8000 is a HMI program interface which can make manual easy. RS232 was choosed as the communicate mode between PC and PLC. RS485 was choosed as communicate between the PLC and HMI, USB cable was used as direct download interface communicating between PC and HMI, which achieves continuously automatic operation of the control system of machine.
The results of the baling and enveloping test show that the machine can achieve continuously automatic working of baling and enveloping of the corn straw and high efficiency and bundles shaping better and stable finished quality. The prototype can be adjusted in real time of bundling envelope parameters. After the late storage, its ensiling effect was better than other store ways. It can be see that the fermentation qualities have been significant improved.
文章首先分析了青贮作物的原理、青贮条件及青贮工艺过程,经对比研究,选择了玉米秸秆圆捆青贮方法;其次通过参考国内外大量文献并多次试验研究出了捆包设计参数对青贮品质的影响并得到了捆包青贮的优化参数;再次,针对青贮参数,建立了捆包模型,并以此设计了打捆包膜机整机的机械结构。上料单元采用了可折叠料斗和刮板链轮机构、打捆单元采用打捆钢辊配合电动推杆机构,包膜单元将塑料膜和旋转支架作为其主要组成部分,同时采用大马力拖拉机作为整机的牵引设备;最后,重点阐述了打捆包膜机的控制单元进行设计过程。本单元能够通过对捆包转速、密实度和包膜层数等可控参数的调整,满足青贮工艺要求。控制单元的硬件采用西门子S7-200 PLC作为控制器,执行元件采用交、直流电机,通过对变频器的控制实现速度的调节,通过多种传感器实现位置检测、速度检测、压力等检测和控制;控制单元的软件采用STEP 7作为PLC的开发编程工具,该软件主要通过梯形图语言编写程序,也可以转换成STL语言同步编写。同时采用WINCC作为监控软件主要实现系统的管理及控制功能,采用EB8000作为HMI的程序界面,方便了工作人员手动操作。PC与PLC之间采用RS232通讯,PLC与HMI之间采用RS485通信,PC与HMI之间则采用USB线直接下载界面,实现了整机控制系统连续自动化操作。
选取粉碎玉米秸秆进行打捆包膜试验,结果表明:该样机能够对打捆包膜参数实时调整,实现玉米秸秆打捆包膜的自动化连续工作,且工作效率高、捆包成形较好、成品质量稳定。经过后期的贮藏,其青贮效果比其他贮藏方式效果有明显改善。
Baling and wrapping machine of maize is a typical mechatronics device. This device can convey the crush corn stalks and bale it with thread, then bag it with plastic film and be stored. With national situation of China as its goal, the technology of corn straw silage has been developed refering to abundant documents, Silage quality parameters are got after lots of experiments .According to these parameters, a new mechatronics device are developed, and the goals of low-cost, high efficiency and high quality automation integrate are achieved.
Firstly, the principle, conditions and the process of ensiling technology of ensiling crops have been analyzed. The method of baling and wrapping of maize which is the most appropriate method is choosed after comparing a variety of ensiling method. Secondly, the effective factors of bundles to the quality of ensiling and reasonable parameters of bale ensiling have been gotten .by referring to a large number of domestic and foreign documents and testing many times. Thirdly, a model of bundles was established for ensiling parameter and the mechanical structure was modeled. In order to guaranting efficiency and quality principles, a folding hopper and scraping board sprocket as material institutions was designed, and Bundling steel roller suit electric putting as playing bundle cabin and plastic film and rotating bracket as the main part of the package film unit , while used the large horsepower tractor as the driven device. Finally, a control system for the bundling coating machine was developed according to the mechanical structure, which can meet the ensiling process requirements by adjusting baling speed, density and coating layer. A Siemens S7-200 PLC was choosed as controller in the hardware of controlling unit, and AC and DC motors are choosed as actuators. Speed regulation is achieved by Frequency converters’control .the location, velocity and pressure are detected by sensors.The software of STEP 7 is choosed as PLC programming tool, which can write ladder diagram and STL language. System of management and control functions are achieved by WINCC . EB8000 is a HMI program interface which can make manual easy. RS232 was choosed as the communicate mode between PC and PLC. RS485 was choosed as communicate between the PLC and HMI, USB cable was used as direct download interface communicating between PC and HMI, which achieves continuously automatic operation of the control system of machine.
The results of the baling and enveloping test show that the machine can achieve continuously automatic working of baling and enveloping of the corn straw and high efficiency and bundles shaping better and stable finished quality. The prototype can be adjusted in real time of bundling envelope parameters. After the late storage, its ensiling effect was better than other store ways. It can be see that the fermentation qualities have been significant improved.
引文
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[3]丛宏斌,李明利,李汝莘,等.4YQK-2型茎秆青贮打捆玉米收获机的设计[J].农业工程学报,2009,25(10):96—100
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[7]杜健民,李旭英,苏成云,等.新鲜饲料作物及作物秸秆高密度成型产品的试验研究[J].安徽农业科学,2007,35(27):8507
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[9]陈月和.玉米秸秆包膜青贮的制做及效益分析[J].饲料饲草,2007(10):28—31
[10]陈海霞,张纯铸,董德军.秸秆青贮工艺与设备的研究[J].农机化研究,2006(1):34—36
[11] Harrison JH, Johnson L, Hunt C.1998.Mechanical processing of corn silage:Looking back two years.Annual Convention.Seattle WA
[12]艾克拜尔,王文兵.优质青贮饲草料调制与品质鉴定及利用技术探讨[J].草食家畜,2004(3):63—65
[13]顾树华,张希良,王革华.能源利用与农业可持续发展.北京:北京出版社,2000:78—80
[14]侯武英.小型袋装青贮机械生产技术[J].农村牧区机械化,2003(2):8—9
[15]刘学清,江波涛,郭春晖.半干青贮饲料的特点及其调制[J].牧草饲料,2007:(9):97～100
[16]张涛,崔宗均,李建平,等.不同发酵类型青贮菌制剂对青贮发酵的影响[J].草业学报,2005(3):67～71
[17]史乐雷,史波.饲料青贮的技术示范与推广措施.畜牧兽医科技信息[J],2004(10):58—59
[18]薛友生.新型青贮机械化技术裹包和袋装技术[J].农机安全监理,2002(12):54
[19]保平.新型袋装青贮饲料装填机的研制.农村牧区机械化[J],2002(1):18—20
[20]徐鹏云.玉米秸秆打捆机参数化设计与仿真.河北农业大学学报[J],2011(1):18—20
[21]魏笑笑,王宝维,刘志杰,等.青贮饲料加工工艺与设备的研究与应用.养殖与饲料[J],2007(12):70—72
[22]翟宏民.青贮料的品质鉴定及有效利用方法.江西饲料[J],2011(5):34—35
[23]申晓蓉,陈士恩,郭鹏辉,等.两种处理方法对青贮玉米饲料营养品质的影响.草原与饲料[J],2011,31(4):54—56
[24]苏序.秸秆青贮技术.养殖世界[J],2007(22):38—39
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