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气吸式 红枣 收获 设计

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气吸式红枣收获机的设计,气吸式,红枣,收获,设计

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第4 卷第3 期农业工程Vol 4No 32014 年 5 月Agricultural EngineeringMay 2014收稿日期:2014-03-27修回日期:2014-04-24作者简介:史高昆，硕士生，研究方向:农业机械化。E-mail:1014951940 qq. com马少辉，通信作者，副教授，硕士生导师，研究方向:农业机械化工程。E-mail:ngynj sina. com气吸式红枣捡拾机设计与试验史高昆，马少辉( 塔里木大学机械电气化工程学院，阿拉尔 843300)摘要:新疆南部地区红枣种植模式以矮化密植为主，红枣收获仍采用人工捡拾，效率较低。基于伯努利原理，设计研制了一种气吸式红枣捡拾机械。以南疆枣园为试验点，对样机的性能和捡拾效率进行了试验。结果表明，吸管口的最佳风速为 23 ms;平均捡拾效率 182. 8 kgh，是人工捡拾的 5. 2 倍。关键词:红枣;捡拾机;气吸式;设计;试验中图分类号:S225. 93文献标识码:A文章编号:2095-1795( 2014) 03-0109-04Design and Experiment of Air- suction ed Dates Picking MachineryShi Gaokun，Ma Shaohui( Academy of Mechanical Electrification Engineering，Tarim University，Alar 843300，China)Abstract:Planting red dates regards the dwarf culture as main planting patterns in south region of XinjiangLow efficiencymanual picking is still used in the process of harvesting red dates A air- suction red dates harvesting machinery was designedbased on the Bernoulli principle Functions and picking efficiency of prototype were tested with the jujube orchards in the southregion of Xinjiang as the test points Experimental results showed that the best wind velocity of straw mouth was 23 ms，averagepicking efficiency was 182. 8 kgh，production efficiency with that machinery was 5. 2 times than that with manual pickingKey words:ed dates，Picking machinery，Air- suction，Design，Experiment0引言矮化密植是现代园艺栽培的方向，其主要利用人工和化学控制的方法使树体矮化，以大幅度提高单产。其优点是提早结果、早期丰产、节约土地、降低投资、树体矮小、管理方便、收回成本早和品种更新快，被广泛应用推广1 。新疆南部 ( 以下简称 “南疆” )地区是我国重要的特色优势瓜果生产基地。2011 年，全区红枣面积已达 30 万 hm2，位居全国第2 位，占全国红枣总面积的 142 。矮化密植模式不利于机械作业的发展，尤其在红枣收获环节机械难在枣树行间作业3 。目前我国在红枣收获机械的研制方面取得一定进展，但是针对矮化密植枣园的收获机械研究较少。新疆农垦科学院研制的 4YS-24 型红枣收获机，通过机械手臂钳住红枣树干并进行低频振动，红枣落入地面的伞形装置内，采净率达 91. 5%，效率是人工的 10 倍，但不适用于矮化密植模式4 。针对南疆红枣种植模式，石河子大学机械电气工程学院研制的 4ZZ-4 型自走式红枣收获机，具有对枣树损伤小、可连续作业和采净率高等优点，缺点是无法收获落地红枣5 。针对以上情况，设计了一种可用于矮化密植枣园收获的红枣捡拾机。该机械具有结构简单、体积小、可靠性高、成本低和效率高等优点，并能一次性完成红枣的捡拾收集和除杂分选。1设计思路设计一种 3 通管道，利用风机吹出的正压经过 3通管道转变风向形成负压，使管道口产生足够的吸力，从而达到捡拾红枣的目的6 。当红枣被吸起经过 3 通管道时，管道截面积逐渐变大，气流速度降低，质量大的红枣落入下方的收集框，质量小的杂质被吸送到集杂袋。根据伯努利原理风压与风速的关系，可计算出具体的风速大小。P +v22+ gh = C( 1)式中P 管道内风流体的压强 风流体的密度v 管道内风流体的线性速度g 重力加速度h 铅垂高度C 常量比值农业工程设计制造及理论研究由公式 ( 1)可知，在单位体积风流体的各参数在沿流线运动过程中，总和保持常量不变。在 h 值保持一致的情况下，风压与风速成反比，风速越大时，风压越小，3 通管道吸口处产生的负压越大，对枣的吸力越强。因此，合理选用风机和设计管道结构，是实现气吸式红枣捡拾的关键。2整机设计2. 1结构及工作原理该机主要由吸管、风机、3 通管道、分选管道、收集框、机架和集杂袋等部件组成 ( 图 1) 。工作时，风机 1 转动产生足够的风速，使吸管 2 产生足够负压，捡拾枣与杂物，当红枣与杂物经吸管 2 进入 3 通管道 3 时，因气流方向改变，3 通管道出口处为正压值，红枣和杂物被气流吹送到分选管道 5 后，因气流管道变大，流速减慢，质量大的红枣落入收集框 6中，枣叶等杂物因质量较小被吹入集尘袋 7 中，完成红枣捡拾和杂物分离过程。1. 风机2. 吸管3. 3 通管道4. 机架5. 分选管道6. 收集框7. 集杂袋图 1气吸式红枣捡拾机整体结构Fig. 1Whole structure of air- suction red dates picking ma-chinery2. 1. 1 3 通管道的设计与原理3 通管道是将风机产生的正风压在吸管内转变成负风压的部件，由直径 12 cm 和 8 cm 的 PVC 管拼接而成，2 根管夹角 10。直径 8 cm 的管与吸管连接，直径 12 cm 的管一端为风机进风口，另一端为出风口。图 2a 中，4 处为风机出口的风速，气流从 1 至 4的过程中管道截面积逐渐变小，气流速度增大，在 2处气流速度最大。此时，气流会从吸管 2 进入，在吸管 2 内产生负压与风机产生的气流一同从管道 3 排出。3 通管道内风速及在截面发生变化后，在管道 2内产生的负压吸附力是关键数据。红枣能被吸起的临界条件即红枣悬浮速度，悬浮速度是负压吸附力对红枣产生的作用力等于红枣重力。该处应满足的条件为质量最大的红枣在最小投影面积时依然能被吸起。根据悬浮速度公式可列平衡方程:图 23 通管道设计原理Fig. 2Design principle of 3 way pipemmaxg 0. 5CdSjV2t= 0( 2)式中mmax 南疆地区单个红枣的最大质量g 重力加速度 空气密度，取 1. 205 kgm3Cd 阻力系数Sj 红枣在运动方向上的投影面积Vt 悬浮速度根据南疆地区红枣标准，mmax取值 0. 036 1 kg，阻力系数 Cd取值 0. 6，红枣在运动方向上的投影面积 Sj取值 0. 003 m2，可得 Vt= 18. 2 ms。同时为保证可靠输送的气流速度，将悬浮速度乘以一个气流速度系数 K ，为了保证红枣能可靠地进行气吸收获，K的取值设为 1. 27 。v = Kvt( 3)式中v 安全风速K 安全系数vt 悬浮速度由公式 ( 3)计算可得安全风速v = 21.8ms。该速度是红枣能被顺利吸起的可靠气流速度，也是选择风机的依据。2. 1. 2分选管道的设计分选管道由截面积逐渐变大的箱体和筛网组成，作用是将红枣与杂质分离。杂质主要是枣树叶及枣吊和土粒构成。红枣与杂质一起进入分选管道中，随着管道截面积的增大，风速降低，质量较大的红枣沉降落入收集框中，质量较小的枣树叶、枣吊、土粒，穿过筛网而被排出分选管道。少数质量较小、没有沉降的红枣被筛网拦下，落入收集框。2. 1. 3风机的选取风机的选取需满足风压要求，即系统整体的风压011史高昆等:气吸式红枣捡拾机设计与试验损失。风压损失主要为动压损失、摩擦压力损失和吸口局部压力损失7 。P = 0. 5v2+4sv22L +( + ) v232( 4)式中s 管道的水力半径，直径为 D 的圆形管道 s=D4 摩擦系数，橡胶 = 0.028 5D0.285V0.01，D = 圆形管道直径v3 橡胶管内气流速度 尘气速度比，通常 = 0. 5 0. 8，取 =0 6n 吸口局部压损系数，取 n=5 混合比，对于收获机 =0. 01 0. 03，取 =0. 02代入数据计算风压为 1 861. 7 Pa，据此选用 F-4S2200 型离心风机。风机的动力选用汽油机，便于田间移动作业。2. 2气吸管道结构仿真与优化气吸管道的关键部件是 3 通管道，其设计关系到捡拾效率、拾净率和燃油消耗。同时，合理的设计能避免管道内产生涡流，减少红枣之间或与管道碰撞造成的破损 8 。对3 通管道仿真能直观了解内部气流运动情况。为了便于仿真，将风机出口简化成直径 6 cm的管道，吸管简化成直径 8 cm 的管道。3 通管道 Flu-ent 仿真简图见图3，压强云图和速度矢量图见图4。a. 风机出口b. 连接吸管c. 连接分选箱图 33 通管道 Fluent 仿真简图Fig. 3Diagram of Fluent simulation for 3 way pipe通过压强云图发现在过渡处出现了压强集中区域，在速度矢量图中的过渡处也出现了紊流区域。该处不仅降低机械效率，而且会导致红枣之间发生碰撞损伤红枣。将此过渡区设计成渐变过渡，使气流运动情况逐渐改变，通过合理的结构设计避免了紊流的出现。图 43 通管道的压强云图和速度矢量图Fig. 4Diagram of pressure contour and velocity vector for 3way pipe3田间试验根据气吸式红枣捡拾机的各设计参数，研制了 1台样机 ( 图 5) 。样机采用汽油机驱动离心式风机。图 5气吸式红枣捡拾机械试验样机Fig. 5Experimental prototype of air- suction red datespicking machinery3. 1试验材料与设备试验材料选用南疆地区种植的一级骏枣;试验设备采用自行设计研制的气吸式红枣捡拾机械，电子称1 台，红枣收集框若干。3. 2试验内容试验地选取新疆生产建设兵团农 1 师 10 团 7 连红枣园。该枣园是 10 团精品示范园，采用矮化密植栽培模式，行距 1. 5 m。( 1) 试验前，人工将红枣与杂质在枣园中的地面上呈自然分布，使枣园中的红枣与收获时模式一致。试验时，单人操作红枣捡拾样机，控制吸管移动捡拾红枣，同时移动整个机械前进。( 2) 试验分 6 组进行，每组重复 3 次，取平均值。1 3 组进行气吸式红枣捡拾机械的性能测试，测得机械最优的风速参数下最好的收获效果。4 6 组用来统计捡拾机械的生产效率。每组试验收获 100 kg 红111农业工程设计制造及理论研究枣，同时统计机械的使用效果与收获效率。( 3) 衡量红枣捡拾机收获性能的指标有拾净率、损失率和含杂率。拾净率是红枣捡拾机械能捡拾的红枣与未捡拾红枣的比值;损失率指红枣被捡拾起，但在分选管道中未能落入收集框而随着杂质一同被排出的红枣质量与所有捡拾的红枣质量的比值;含杂率指进入收集框的杂物质量与红枣质量的比值。4试验结果与分析4. 1性能指标试验时，通过改变汽油机油门大小实现控制风机转速，从而调整吸管口的吸附风力大小;通过风速计测得吸管吸附风力最小值为 17 ms，最大值为27 ms，以 2 ms 为步进量，称质量计算出每组的拾净率、损失率及含杂率 3 个性能指标的数据，如表 1 所示。表 1气吸式红枣捡拾机性能测试结果Tab. 1Performance test results of air- suction red dates pickingmachinery风速ms1171921232527拾净率%77. 0086. 5093. 5198. 6399. 1099. 65损失率%0. 200. 340. 420. 531. 872. 52含杂率%2. 232. 101. 450. 870. 590. 46由表 1 可知，风速越大，拾净率越高、损失率增加、含杂率降低。通过正交试验分析，吸管口的吸附风速为 23 ms 时，各项指标较优。4. 2捡拾效率根据气吸式红枣捡拾机的性能测试结果，选择吸管口吸附风速为 23 ms 作为气吸式红枣捡拾的风速指标，进行 5 组收获生产效率试验，试验结果如表 2所示。由表 2 可知，气吸式红枣捡拾机的平均捡拾效率是 182. 8 kgh，而南疆地区农 1 师团场枣园人工捡拾生产率只有 35 kgh。与人工捡拾相比，气吸式红枣捡拾机械的生产效率是人工捡拾的 5. 2 倍。表 2气吸式红枣捡拾机捡拾效率Tab. 2Picking efficiency of air- suction red dates picking machin-ery序号纯捡拾红枣生产率kgh1包含辅助操作实际生产率kgh1辅助操作减少的生产率与纯加工生产率的比值%第 1 组187. 0169. 09. 63第 2 组194. 0173. 010. 83第 3 组173. 0158. 08. 67第 4 组179. 0161. 010. 06第 5 组181. 0170. 07. 73平均182. 8166. 29. 385结束语针对南疆地区红枣人工捡拾收获的现状，根据伯努利原理，设计研制了气吸式红枣捡拾机械，通过收获试验，验证了气吸式捡拾红枣的可行性。通过试验测试，气吸式红枣捡拾机吸管口的最优吸附风速为23 ms。实地红枣捡拾试验表明，气吸式红枣捡拾机的生产率为 182. 8 kgh，是人工捡拾的 5. 2 倍。参考文献 1杨红英，坎杂，王丽红，等矮化密植红枣采收装置的设计J 农机化研究，2012，34( 6) :77-80Yang Hongying，Kan Za，Wang Lihong，et alDesigning equip-ment of dwarf and close planting jujube harvestJ Journal of Agri-cultural Mechanization esearch，2012，34( 6) :77-80 2史彦江，宋锋惠 红枣在新疆的发展前景及对策J新疆农业科学，2005，42( 6) :418-422Shi Yanjiang，Song FenghuiDevelopment prospect and counterp-lan of ziziphus jujube in XinjiangJXinjiang Agricultural Sci-ences，2005，42( 6) :418-422 3付威，何荣，曲金丽，等 自走式矮化密植红枣收获机的设计J 农机化研究，2014( 4) :106-109Fu Wei，He ong，Qu Jinli，et al Design of self-propelled dwarfand close planting jujube harvesterJJournal of AgriculturalMechanization esearch，2014( 4) :106-109 4孟祥金，汤智辉，沈从举，等 4YS-24 型红枣收获机J新疆农机化，2013( 1) :13-14 5付威，杨红英，王丽红，等 4ZZ-4 型自走式红枣收获机J湖南农机，2012，39( 5) :68-69Fu Wei，Yang Hongying，Wang Lihong，et al 4ZZ-4 type self-propelled dates harvester JHunan Agricultural Machinery，2012，39( 5) :68-69 6庞昌乐，鄂卓茂，苏聪英，等 气吸式双层滚筒水稻播种器设计与试验研究J 农业工程学报，2000，16( 5) :52-55Pang Changle，E Zhuomao，Su Congying，et alDesign and ex-perimental study on air-suction two-layer cylinder rice seederJTransactions of the Chinese Society of Agricultural Engineering，2000，16( 5) :52-55 7孙勇 真空吸尘车气路系统优化设计与仿真分析D沈阳:东北大学，2008Sun Yong Design optimization and simulation analysis on pneumaticsystem on vacuum sweeperD Shenyang:Northeastern Universi-ty，2008 8左彦军，马旭，玉大略，等 水稻芽种窝眼窄缝式气吸滚筒排种器流场模拟与试验J 农业机械学报，2011，42( 2) :58-62Zuo Yanjun，Ma Xu，Yu Dalue，et al Flow field numerical simu-lation of suction cylinder-seeder for rice bud seed with socket-slotJ Transactions of the Chinese Society for Agricultural Machiner-y，2011，42( 2) :58-622112 0 0 9 年第5 期 新疆农机化 国 外 农 机 ： 一 约翰迪尔 7 7 6 0自走式可打包棉花收获机 约翰迪尔 7 7 6 0自走式可打包棉花收获机是 由 美 国迪尔公 司于 2 0 0 7年推 出的世界上最先进的新 一代 自走式摘棉机 ，由一 台摘棉机和一台机载的圆 形棉花打包机组成。它的诞生体现了迪尔公司在棉 花收获机械技术上的世界领先地位 ，实现 了机械收 获棉花的一次革命，即田问采棉和机载打包一次完 成 ，实现连续不问断的田间采棉作业。该机具有 的 主要特点： 1 进行连续不停 顿的 田间采摘收获作 业 7 7 6 0棉花收获机柴油箱容积 1 1 3 6 L ，摘锭清 洗液箱容积 1 3 6 3 L ， 采棉头润 滑脂箱容 积 3 0 3 L 。 每天加注一次液体可 以在 田间连续采棉作业 1 2 h 以上 。 据美国农场主经过 2 0 0 8 年棉花采摘季节的实 践， 与传统的棉箱式摘棉机相比， 相同作业面积时， 7 7 6 0 棉花收获机在采摘作业时间上平均可以节约 2 0 - 3 0 ， 大幅度提高 了棉花采摘效率。当用时间 作为衡量棉花采摘作业的要素时，这种效率的提高 无异是帮助摘棉机用户节约了费用 。 2 节 约 了田间采摘 作业 时需 要的人 力和 相 关配套 的设 备 在采摘作业中，该机只需要把机载的圆形棉花 打包机弹出的棉花包放置在机器后面的一个可升降 的托架上 ， 继续进行采摘作业 。等该机到地边时， 直 接把棉包卸载到地面上。仅需要配备一个拖拉机后 置式的棉包叉车和一辆棉包运输车。减少了传统的 棉箱式摘棉机作业时必须配套的运棉车、牵引运棉 车的拖拉机或传统的方形棉花打垛机等设备 ，农场 棉机一样的摘锭清洗功能， 确保了最大的收获效率。 7 底盘 5 棉花输 送系统 该机使用了在约翰迪尔自走式摘棉机上验证多 年的 J E T A I R T R O L棉花输送 系统 ， 确保收获更干 净的籽棉 。 棉花输送系统 由一个风机和两个输棉管组成 ， 每个采棉头都有一个单独的通向棉箱的输棉管。即 使在最小动力输出时 ，该系统也能够提供出色的籽 棉输送效率。此外，该系统使采摘头被阻塞的可能 性降为最低。棉花输送系统 由牵引拖拉机的后动力 输出轴提供动力。 6 棉箱 棉箱容积 l 3 m3 ，最大籽棉装载量约 1 0 0 0 k g 。 棉箱的升起和下降通过在拖拉机驾驶室 内操作液压 输 出阀手柄完成的。 棉箱系统包含一个手动接合的棉箱油缸锁 。当 棉箱在升起并锁定的情况下 ，这个装置保证了可以 安全地完成各项维修保养工作。 棉箱后部有一个梯子 ， 棉箱上有安全扶手 ， 为清 理棉箱顶部提供了便利。 该机在牵引拖拉机和摘棉机之间 ，实现了可转 向的联结。该装置允许驾驶员在拖拉机驾驶室进行 道路运输状态 ( 正牵引模式 ) 和 田间采摘作业 ( 右置 侧牵引模式 )两种模式下的牵引状态转换操作 。此 外 ， 该装置还可以减小转弯半径 。 在道路行走时， 使用道路运输牵引模式。 这种牵 引模式也被用来在棉田首次采摘开路时使用。当棉 田采摘通路被打开后，将牵引方式转换成田间采摘 作业模式 ， 使两个采摘头始终在拖拉机 的右侧工作。 该机与牵引拖拉机之间的悬挂连接和分离非常 方便快捷。 在从牵引拖拉机上分离摘棉机时 ， 驾驶员 先放下停车支架 ， 卸掉动力输 出轴 ， 从液压输出阀上 拔 出液压管 ，从拖拉机后部断开电线插头和断开拖 拉机牵引杆。三个人在 1 mi n之内就可 以完成悬挂 连接或分离 。 约翰迪尔 7 2 6 0牵引式摘棉机在中亚地 区、 中国 新疆已经连续数年进行了田间棉花采摘作业 。实践 证明 ，该机完全适合在中小规模棉花种植规模下对 棉花机械化收获的需求。 ( 约翰迪 尔中国市场部 ) 61 国 外 农 机 新疆农机化 2 0 0 9 年第5 期 主明显减少了在棉花采摘季节需要雇用的辅助劳动 力人数 ，也减少 了在 田间需要搬运棉花方形打垛机 的麻烦。 当 7 7 6 0棉花收获机需要从一块棉 田转移到另 一块棉 田时 ，可以在 1 m i n之内从采摘模式转换到 运输模式 ，允许驾驶员非常轻松地 以 2 7 k m h的速 度在道路上行驶。 不论是摘棉机在 田间采摘棉花 ，还是从一块棉 田转移到另一块棉田， 7 7 6 0 棉花收获机都把棉花机 械化收获提高到了一个新的水平，创造了一种简单 高效的棉花机械化收获方式。 3 动力 强劲 ，能够 保证在 各种条件 下棉 田 的采摘作业 约翰迪尔 7 7 6 0自走式可打包棉花收获机 配备 了约翰迪尔 P O WE R T E C H P L u 排 气量 1 3 5 L 、 额定功率 3 7 0 k W、 符合 T I E R I I I 排放标准的柴油发 动机。P r o D r i v e 自动换档的变速箱 ， 允许驾驶员在 行进时实现平稳变速。 一档采摘速度可达 6 8 k m h ， 道路运输速度可达 2 7 4 k m h 。静液压四轮驱动， 保 证强大、高效的驱动能力。适应各种条件下棉 田的 采摘作业 ，甚至能够在泥泞和有积水的棉田中进行 采摘作业 。 2 0 0 8 年 ，美 国路易斯安那州飓风灾害发生后 ， 当其它型号自 走式摘棉机都无法在有积水的棉田中 继续采摘作业时 ， 只有约翰迪尔 7 7 6 0自走式可打包 棉花收获机能够在泥泞的棉田继续进行采摘作业。 4 适应全天候条件下的采摘作 业 约翰迪尔 7 7 6 0自走式可打包棉花收获机 的机 载圆形打包机把圆形棉包包裹三层 ，棉包最大直径 可达 2 2 9 m( 直径可调范围 0 9 1 2 2 9 1 1 3 ) ， 宽度 2 。 4 3 m， 每包籽棉重量 2 0 3 9 - 2 2 6 5 k g 。与传统的方形棉 花垛相比， 网形棉包改善了雨天的防水性能 ，具有 抗风、 运输过程中不易破损等特点， 圆形棉包的高强 度打包膜从 田间到轧花厂的过程中，很好地保护 了 棉花纤维和棉花种子。 圆形棉包与地面接触面积小 ，对存放场地没有 特殊要求 ， 不需要专 门的运输车辆。具有拉运方便 、 在田问和轧花厂存放方便的特点。圆形棉花包被全 部包裹 ，减少 了在 田问和轧花厂存放场地上的籽棉 损失 。 6 2 5 有利于轧花厂 的加工 在棉花的收获和加工季节， 对轧花厂来说， 籽棉 的运输和存放是非常困难的。圆形棉包具有形状大 小一致 ， 内部湿度恒定和密度均匀 ， 运输和存放灵活 方便的特点。 使用 7 7 6 0棉花收获机收获的棉花 ， 给轧花厂拉 运籽棉尤其是在雨天拉运籽棉带来了极大的便利 。 运输圆形棉花包时，首先使用拖拉机后置式叉 车在田间将棉花包分段运输，再使用标准的方形棉 花垛运输卡车或平板卡车将圆形棉花包运走。一辆 标准的方形棉花垛运输卡车每次可以装运四个圆形 棉花包 ，长 1 4 6 4 i n的平板卡车一次可 以装载 6个 圆形棉花包 ， 1 6 1 7 m的平板卡车一次可 以装载 7 个圆形棉花包。 圆形棉花包被全部包裹 ，从田间到轧花厂包中 的籽棉几乎不损失 。 在加工圆形棉花包时 ， 由于圆形 棉花包不会在场地上散落棉花 ，轧花厂也不需要专 门派人来清理 。而传统的方形棉花垛堆放在轧花厂 场地上会吸收地上 的水分并容易受雨水 的侵蚀 ， 在 喂人轧花加工线前 ， 需要烘干处理 、 把脏棉花人工分 捡出来。而全包裹的圆形棉花包从 田间到轧花厂的 场院、 轧花加工线一直能保持籽棉的干燥 。 圆形棉花包中的含水量恒定在大约 8 5 ， 因此 棉花烘干需求的炉温低 、 时间短， 所以轧花加工线每 小时大约平均可以增加 7 包 的喂入量。 此外 ， 由于圆 形棉花包里的籽棉静电减少了，所以在轧花加工线 上喂入来 自圆形棉花包 中的籽棉时，要 比喂人方形 棉花垛中的籽棉更容易了。据美国德克萨斯州的一 个轧花厂测算， 在 2 0 0 8 年秋季发生飓风期间， 他们 在雨天加工圆形的棉花包时 ， 节省了 4 0 的用于烘 干籽棉的燃料。 另外 ， 圆形棉花包的包装膜完全可以 回收再利用 ， 也成为 了轧花厂的一笔额外收人 。 经过美国 2 0 0 8 年棉花收获季节 的实践， 约翰迪 尔 7 7 6 0自走式可打包棉花收获机得到了棉花农场 主和轧花厂的普遍好评。该机不仅实现了田间连续 不停顿的采摘作业，使农场主提高了棉花收获的采 摘效率。 而且， 紧凑的圆形棉花包帮助轧花厂减少了 籽棉的损失和棉花等级的降低，也为轧花厂提供了 籽棉拉运和存放的灵活性和方便性，并提高了轧花 加工线的加工效率。 ( 约翰迪 尔中国市场部) 2950 Niles Road, StJosepli _ 49085-9659, USA 269.429-0300 fax 26S.4293SS2 hc|# An ASABE Meeting Presentation Paper Number: 0844697760 Cotton PickerJason D. WattonvilleJohn Deere Des Moines Works, Ankeny, Iowa, USAWritten for presentation at the 2008 ASABE Annual International Meeting Sponsored by ASABE Rhode Island Convention Center Providence, Rhode Island June 29 - July 2，2008Abstract. The John Deere 7760 Cotton Picker, with on-board module building technology, offers customers the next revolution to cotton harvesting machinery. The 7760 breaks through the productivity barrier by way of virtual non-stop harvest. The 7760 can harvest non-stop or continuously pick while forming, wrapping, ejecting and carrying a round module. Building round modules on-board the machine eliminates most field support equipment and the additional labor and costs associated with it. Wrapping the round modules in waterproof plastic wrap provides better protection to preserve cotton fiber and cotton seed quality while containing the cotton in the module so minimal cotton is lost during handling and transport. Some other key features of the 7760 include a Tier III emissions compliant 13.5L engine (500 hp), Pro Drive powershift transmission, CAN BUS electronics, updated operator station, and improved serviceability and diagnostics.Keywords. Agricultural Equipment, Cotton, Cotton Harvesters, Farm Machinery, Harvesting MachineryThe authors are solely responsible for the content of this technical presentation. The technical presentation does not necessarily reflect the official position of the American Society of Agricultural and Biological Engineers (ASABE), and its printing and distribution does not constitute an endorsement of views which may be expressed. Technical presentations are not subject to the formal peer review process by ASABE editorial committees; therefore, they are not to be presented as refereed publications. Citation of this work should state that it is ftorn an ASABE meeting paper. EXAMPLE: Authors Last Name, Initials. 2008. Title of Presentation. ASABE Paper No. 08-. St. Joseph, Mich.: ASABE. For information about securing permission to reprint or reproduce a technical presentation, please contact ASABE at iutter or 269-429-0300 (2950 Niles Road, St. Joseph, Ml 49085-9659 USA).7760 Cotton PickerIntroductionFeedback from a worldwide customer base, representing all segments of the cotton industry, expressed the need to enhance and improve the entire cotton production chain a chain that includes harvesting, handling, transporting and ginning seed cotton. The overall customer request was to help us- reduce our labor, reduce our assets, increase our flexibility and help us preserve fiber quality. To provide a solution of increased efficiency and profitability, we needed a systematic paradigm shift (see Figure 1) which involved 3 groups of constituents: farmers, transporters and ginners. Input from those constituents helped define the requirements for a new generation cotton harvester, the John Deere 7760 Cotton Picker. Equipped with built-in module-building technology, the 7760 is a revolutionary cotton-harvesting machine which streamlines the stages of cotton production, from the initial picking of the plant to the completion of the lint bale.Figure 1, 7760 Harvesting System Approachproject DescriptionFigCire 2. Current Basket Picker Harvesting ProcessTypically, every 6 row cotton picker requires four pieces of support equipment along with labor to operate that equipment (see Figure 2). The labor, cost and management challenges associated with supporting cotton harvest is one of the primary drivers and inspiration for the 7760 and producing round modules on-board the harvester.Development of producing modules on-board cotton pickers began as far back at the 80s.John Deere began experimenting with various packaging techniques to determine optimum size and shape for building cotton modules on-board the cotton harvester.Since the industry had standardized on conventional modules, early experiments involved partitioning a conventional module builder to evaluate partial size modules. The major issues to be addressed with this concept were: 1) the lack of module integrity; 2) the low package (module) density; 3) the requirement of the vehicle to stop for module unloading. These issues would have contributed to higher transportation costs, lower ginning efficiency and unimproved or reduced harvesting productivity. Additionally, the smaller “mini” modules did not offer improvements in handling, transportation or improvements to fiber preservation. Since these issues resulted in not meeting the requirements that our customers were asking for, the focus was turned to an alternate package type, the round module (bale). The first advantage we saw in the round shape was that it sheds water naturally and lends itself to being covered automatically. A waterproof protective covering completely around the circumference of the round module helps preserve the fiber and reduce seed cotton losses incurred by handling and/or transportation.Additionally, the round module enables the 7760 to harvest non-stop resulting in a dramatic machine productivity increase of 20% or more. The 7760 eliminates the time spent unloading, waiting for boll buggies, or driving back and forth to a module builder as round modules can be wrapped, ejected, carried and dropped at the turn row without ever needing to stop themachine. The non-stop harvesting function of the 7760 Picker trims approximately five days off of the typical four-week harvest.The vision for this program is as follows: Reduce labor requirements Improve asset utilization Increase productivity Lower harvesting costs Preserve cotton fiber and reduce losses Increase handling and transportation optionThe performance requirements for this vehicle are outlined in Table 1. In many cases, our requirements were based against the current 9996 cotton picker since it has and continues to be the market leader in the 6 row class of cotton pickers.Table 1: 7760 Performance RequirementsModel7760Productivity increase over 999620%Ability to non-stop harvest (up to 4 bale/acre yields at 4.2 mph)YesFluid capacity12 hrs ContinuousImproved shift-abilityYesLocked wheel during powered brake turnYesField transport heightEquivalent to 9996Shipping heightEquivalent to 9996FlotationEqual or greater than 9996Tractive efficiencyEqual or greater than 9996Tractive effortEqual or greater than 9996Standard front dual drive tiresYesOption single front drive tiresNoImproved maneuverability over 9996YesTier III emissions compliant YesAccumulator Round Module Builderj Wrap MechanismFigure 3. Machine Cut-AwayTheory of Operationi he following section describes the theory of operation of the round module building process on-board the 7760. Please refer to Figure 3 in this section.AccumulatorAccumulator technology and monitoring provides an 8.5 mA3 (300 ftA3) chamber or buffer that temporarily stores 1000-1200 lb seed cotton during the wrap and eject process. This buffer is what allows the machine to harvest non-stop.The accumulator working in conjunction with a double reverse flighted auger ensures an even and uniform flow of cotton is delivered to the round module builder resulting in consistent cylindrical formed round modules in all conditions.Mounted to the top of the accumulator is the lid extension and hood. It contains perforated screens and fingergrates that provide a means to separate trash from the cotton and also provides self-raising and lowering of the ducts.Sensors monitor the level of cotton within the accumulator to start and stop the feeding process fom the accumulator into the round module builder.Feed rolls convey cotton from the accumulator to the feeder belt. The feed roll metering system is patented technology.FeederCotton received from the accumulator feed rolls is transported via a rubber belt and compressed between this belt and a laydown roller resulting in a uniform ribbon (or mat) of cotton presented to the entrance or throat of the round module builder. The feeder is also patented technology developed jointly between John Deere and PA Consulting.Round Module BuilderThe round module builder has the capability to automatically build, wrap, eject (on demand), and drop uniform and consistent modules without stopping the machine. The round module builder is powered by an electronic controlled hydrostatic system that operates in conjunction with the feeder system.The round modules can be variable in size up to the target diameter of 2439 mm (90，）and a width of 2388mm (94，）and will weigh approximately 5000 lbs depending on moisture content of the cotton. This size of module will allow unloading on one end of the field in all but extreme operating conditions (high yields and long rows).Portioned Wrap & Wrap SystemThe round module covering consists of an industry first portioned wrap (eliminates a cutting mechanism) made of a non-contaminating LLDPE material. LLDPE, is the same material used for lint bale covers today and is recyclable. The wrap will provide package integrity, puncture resistance, and full surface coverage with an edge-wrap feature (CoverEdge) to provide weather resistant protection for the seed cotton package. Wrap will be provided in rolls that weigh 100 kg (220 lbs) and contain 22 portions.The wrap mechanism will have the capability to separate the portioned wrap as it is applied to the round module during the wrapping process. Fully loaded, the machine can carry 110 wraps (five rolls). One roll is positioned in the wrap mechanism with four .additional rolls in the magazine. This provides more than enough wraps to complete a 12 hour harvest day.HandlerThe handler carries a round module to the desired field staging location. It also provides a means to lower the round module builder down to an acceptable shipping and field transport height. The rear gate of the round module builder rests in slots located on the handler which guides the builder into this configuration. Figure 4 shows the machine in field transport configuration.Figure 4. Field transport positionltAuto Mode Module BuildingAuto mode enables the machine via electronics, hydraulics, software and sensors to automatically control the building of each round module. “Auto” mode is engaged by pushing one button on the hydro handle alleviating the complexity of module making.During the automated round module building process, the comerpost and armrest displays provide clear and concise feedback to the operator indicating exactly where the machine is at in executing the process.The round module builder or baler does not run continuous, but rather cycles on and off as needed. The cycle is controlled by 2 sets of infrared through-beam sensors. The upper sensors sense when the accumulator is full, initiating the module building cycle to start. The cycle continues until the lower set of sensors are activated stopping the cycle. This repeats itself until the round module reaches its maximum diameter of 90，. When it reaches 90”，the cotton flowing from the accumulator is stopped and the wrap cycle is automatically initiated wrapping the round module. After the round module is wrapped, the operator interface asks the operator to eject. Confirmation is required to eject the round module out onto the handler. Cotton continues to pour into the accumulator during the wrap and eject cycle. After the round module has been ejected and the gate closes, the system is ready to repeat itself.Key FeaturesNon-Stop Harvest“Auto mode, described in the previous section, enables the machine to automatically control the building of each round module allowing the picker to harvest continuously while forming, wrapping, ejecting and unloading round modules from the machine. Eliminating stops, for any reason, keeps the picker harvesting cotton.Operator StationThe 7760 features a newly designed cab for a much improved operators environment. New operator interfaces have been added that include a CommandCenter display mounted to the revised and updated armrest (see Figures 5 and 6). The cab layout has been revised to provide for an LCD based Cornerpost Display, updated armrest control locations, Harvest Doc Cotton ready, and overhead console revisions. With the addition of the CommandCenter display, information such as internal alarms, diagnostic trouble codes, diagnostic addresses, calibrations, mode management setup screens, set point adjust, and text displayed messages are available to the operator. The addition of the LCD based Cornerpost Display Unit provides for a dedicated round module builder display (see Figure 6), as well as a display for general harvest monitoring. Harvest warning indicators have been added for complete operator warning annunciation.Figure 5. The all-new CommandCenter display and CommandTouch consolejepijnq a|npoiu punoj pjeoq-uo am oj |oiuoo o!6o| 6u!p!AOJd Aq e|q!ssod BujiseAjeq dojs-uou seiBLU Lp!i|M BunseAjeii epoiu 。雨 6u!p!Aaid joj euoq|oeq s! ainpsijipje Sim S0SS9UJB4 6uu|m jo uo!pnp9J pue sAe|ej uo,!oi!|a ai|i sesn“o jeqiunu am eonpej SJ01U9O j0Mod 9两s-p!|0s Lji!M uo!ounfuo3 u! pesn sjeea uiiop Xq pedo|eyep |sjs|ojituoo ,xoq xey, uo peseq s! ajeMpjei ei|i sejijiiqedBO o!isou6e!p p9A0duj! 9|q!jediuo3 JosjApy 90|AJ9S s! pue s|ooo!ojd NVO pjepues Aflsnpu! luejjno uo psseq s! ainp列ipje |eo!jp9|9 ei|j_so!uono&i3 pasegAeds;p jsodjaujoo _9 3jn6|jElectronic Unit SynchronizationCurrently, picking unit synchronization to ground speed is done via a mechanical link between the ground drive and unit drive hydrostatic pumps. Each machine requires adjustment as part of the manufacturing process. The 7760 program has developed the electronic unit speed synchronization system. This technology eliminates the synchronization adjustment in manufacturing and delivers synchronized unit speed at picking speeds up to 4.2 mph. The improved range of synchronization improves the picking efficiency of the machine. System calibrations provide for precise and accurate control of the picking unit speeds for the entire harvest range.ProDrive Automatic Shift TransmissionThe 7760 also has a new electronic controlled 2-speed powershift transmission with automatic shifting and independent hydraulic wet disc brake design with an integrated spring applied, hydraulic released park brake. Increased tractive effort and higher loads will be carried through a high capacity four pinion differential with hydraulically actuated differential lock to more effectively and reliably transfer the power to the ground in adverse as well as normal conditions.Electronic Controlled Variable Speed Hydrostatic Ground DriveProDrive Automatic-ShiftTransmission (AST) Picking Mode 6.8 kph (4.2 mph) Scrapping Mode 8.1 kph (5.0 mph) Field Transport Mode 14.5 kph (9.0 mph) Road Transport Mode 27.4 kph (17.0 mph)Power ModuleThe heart within the power module is a tier III emission certified 13.5L John Deere PowerTechPlus engine rated at 373 kW (500 HP) 2100 RPM. Coupled to this powerplant is a direct drive pump drive gearbox which provides efficient transfer of power to the hydrostatic, hydraulic systems and cotton fans.Walk-under MainframeThe new mainframe design allows walk-under clearance into the power-module area to improve access into the engine compartment for daily service and maintenance.Air SystemIn order to meet the increased cotton conveying demands due to increasing ground speed to 4.2 mph, twin high efficiency fans deliver improved air flow rates and consume less power.Mechanical Rear Drive AxleThe on-board cotton handling/moduling system added nearly 20,000 lbs of weight to the rear axle compared to our current 9996 cotton harvester.A new rear axle and tire size (see Figure 7) were developed to address higher vehicle weights (without increasing ground compaction), increased tractive effort requirements and increased maneuverability requirements.Figure 7. Mechanical rear axleBy converting to larger radial constructed rear tires, ground compaction under the rear tires remains comparable to the 9996. The static loaded rolling radius increased 30% over the 9996.The new rear axle is powered 100% of the time by an electronically controlled hydrostatic system. This system works in conjunction with the front axle hydrostatic system to provide increased rim pull while maintaining current transport speed. This translates into a machine that is better at climbing hills and is less prone to getting stuck in muddy conditions.Improvements to turning radius over the 9996 cotton picker, in light of a 20% increase in vehicle wheelbase, are possible due to a 55-degree steer angle, a 34% increase in steer angle over the 9996. This results in improved vehicle maneuverability over the 9996 by actually reducing the vehicle turning radius by over 36%. This reduction allows the machine to turn back on the adjacent unpicked rows without requiring the use of power hydraulic brakes or making a three point turn, resulting in less structural stress, less power, and less time to make the turn.Spec ComparisonRear axle weight comparisons9996= 18,000 lbs 7760 = 38,000 lbs 111% increase in rear axle weight Tread setting optionsSame for both a 9996 and 7760 - 30,32,36,38 & 40 in Oscillation comparison 9996 = 8.3 deg 7760 = 9.0 deg8.4% increase oscillation angle Wheel base comparison9996= 141 (3.58m)7760 = 170 (4.32m)20.6% increase in wheel base Steer angle comparison 9996 = 41 deg 7760 = 55 deg34.1 % increase in steer angleTurning radius comparison (6 row heads require tighter turning radius to turn back on adjacent 6 rows)9996 = 236” (5.99m)7760 = 150”（3.81m)36.4% reduction in turning radiusGround compactionWithin 2-3 psi of 9996Round Module HandlingFigure 9. Round Module Handler CM1100Figure 8. Staging Round ModulesIt was already mentioned that the round shape sheds water and the plastic wrap protects the fiber. Some other notable advantages of the round modules include water protection and reduced waste during moving. Notice how the cover-edge on the round module keeps the water away from the fiber (see Figure 10) when exposed to ponding rainfall. And when the round modules are moved, theres typically less waste as well. Typical waste or cotton left behind in the field and gin yard when moving conventional modules (see Figure 11).Once the cotton is harvested, the round modules are easily staged for conventional module truck pick-up (see Figure 8), moved to high ground if necessary, or loaded for transport. The Frontier Round Module Handler CM 1100，coupled to an 8000 series John Deere tractor, provides an effective solution to move, stage or load round modules (see Figure 9) and also provides the flexibility to do these operations when convenient and when circumstances and manpower allow.11Table 2: Machine SpecificationsFigure 10. Round Modules in Standing WaterFigure 11. Waste from Conventional ModulesModule TransportingThe round modules provide additional flexibility for transporting seed cotton to the gin as either a traditional module truck (see Figure 12), with the chain bed modified slightly, or a standard flatbed trailer can be used (see Figure 13).Figure 12. Conventional Module TruckFigure 13. Flatbed TrailersGinningWeve invested a tremendous amount of engineering time and energy to make sure that the round modules are uniform. Uniform in size, density and moisture. This uniformity has proven to be very beneficial to the ginning process. Ginning experts that have experienced ginning round modules agree that it typically gins easier and faster. Shown in Figure 14 is the new Stover Gin Improvement System with capability to automatically process round modules at the gin.Figure 14. Stover GISConclusionIn summary, the 7760 cotton picker is a complete paradigm shift from previous new product programs by not only providing a revolutionary new picker, but by also providing a broad based solution, one that benefits all segments of the value chain and are vital to the long term sustainability of cotton production.By taking a system level approach, the following was achieved:Increased Productivity by Providing Non-stop HarvestFlexible Handling OptionsMore Consistent GinningOpportunity for Better Preserved Fiber QualitySolving technologically challenging problems resulted in a non-stop harvesting system that took a quantum leap forward in