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13屆畢業(yè)設(shè)計(jì)彈指式小型紅棗撿拾機(jī)設(shè)計(jì)說(shuō)明書 學(xué)生姓名 聶 劍 學(xué) 號(hào) 8031209225 所屬學(xué)院 機(jī)械電氣化工程學(xué)院 專 業(yè) 農(nóng)業(yè)機(jī)械化及其自動(dòng)化 班 級(jí) 13-2 指導(dǎo)教師 范修文 日 期 2013.05 塔里木大學(xué)機(jī)械電氣化工程學(xué)院制前 言紅棗是我國(guó)廣泛種植的特色林果,其種植面積和產(chǎn)量占全世界的 99。紅棗中含有豐富的蘆丁、環(huán)磷酸腺苷,能夠防止和治療心腦血管疾病,具有抗過(guò)敏作用,抑制癌細(xì)胞生長(zhǎng)并促進(jìn)癌細(xì)胞轉(zhuǎn)化成正常細(xì)胞的功能,其經(jīng)濟(jì)價(jià)值和藥用價(jià)值極高。地處歐亞大陸腹地,干旱少雨,日照長(zhǎng),光熱資源豐富,晝夜溫差大,適宜栽培品質(zhì)優(yōu)良、產(chǎn)量高的紅棗。近年來(lái),紅棗的種植面積不斷增長(zhǎng),目前紅棗的種植面積近26.7萬(wàn)平方千米。但紅棗的收獲主要依賴于人工,勞動(dòng)強(qiáng)度大、效率低、成本高,且收獲季節(jié)多與棉花等其它經(jīng)濟(jì)作物收獲期重合,導(dǎo)致雇工極其困難,不能適時(shí)收獲,造成不必要的損失。隨著紅棗規(guī)?;?、產(chǎn)業(yè)化發(fā)展,依靠人工收獲已不能滿足紅棗產(chǎn)業(yè)化生產(chǎn)的需求,實(shí)現(xiàn)紅棗機(jī)械化收獲已是紅棗產(chǎn)業(yè)發(fā)展的必然趨勢(shì)。 關(guān)鍵詞:紅棗;機(jī)械化;采收 目 錄 1緒論11.1課題研究的意義11.2國(guó)內(nèi)外現(xiàn)狀及分析11.3.研究的內(nèi)容和方法22彈指式紅棗撿拾機(jī)的結(jié)構(gòu)設(shè)計(jì)22.1總體設(shè)計(jì)方案22.2各個(gè)主要部件的結(jié)構(gòu)示意圖及其功能32.2動(dòng)力的選擇52.3設(shè)計(jì)要求52.4設(shè)計(jì)方案53彈指式紅棗撿拾機(jī)的零件設(shè)計(jì)53.1 計(jì)算撿拾棍帶輪直徑及轉(zhuǎn)速53.2 V帶的選取63.3 V帶線速度的檢驗(yàn)73.4 計(jì)算中心距及基準(zhǔn)長(zhǎng)度73.5計(jì)算A型普通v帶根數(shù)83.6求作用在帶輪軸上的壓力83.7計(jì)算帶傳動(dòng)作用在軸上的力(簡(jiǎn)稱壓軸力)93.8 撿拾裝置帶輪結(jié)構(gòu)參數(shù)93.9撿拾裝置軸與齒輪的計(jì)算10總結(jié)16致 謝16參考文獻(xiàn)18 塔里木大學(xué)畢業(yè)設(shè)計(jì)1緒論1.1課題研究的意義據(jù)史料記載,棗是原產(chǎn)中國(guó)的傳統(tǒng)名優(yōu)特產(chǎn)樹種。經(jīng)考古學(xué)家從新鄭斐李崗文化遺址中發(fā)現(xiàn)棗核化石,證明棗在我國(guó)已有8000多年歷史。隨著紅棗的種植面積的增加,紅棗的機(jī)械化作業(yè)在紅棗栽培中的重要性逐漸凸顯。依據(jù)最近幾年林果業(yè)發(fā)展的態(tài)式分析,果樹種植每年以10%的速度遞增,由于林果業(yè)的快速發(fā)展,各地已形成了較大的種植規(guī)模,每到收獲季節(jié)需要投入大量的勞力來(lái)完成水果采收。可以預(yù)見(jiàn)到,再過(guò)35 年,新種植的果樹進(jìn)入盛果期后, 水果采收作業(yè)將會(huì)出現(xiàn)因勞動(dòng)力短缺、采收不及時(shí),而直接影響果品質(zhì)量和造成大量損失的問(wèn)題。這是因?yàn)?,水果采摘是一?xiàng)勞動(dòng)投入量很大的作業(yè),有些水果因成熟期不一致,需要多次采摘才能完成收獲;另外,水果收獲是在離地面有35 m高的空中作業(yè),以上原因決定了水果采摘是一項(xiàng)費(fèi)時(shí)、費(fèi)工、費(fèi)力的作業(yè)。人工采收水果的速度緩慢,大面積發(fā)展水果種植時(shí),必須要依靠機(jī)械化來(lái)提高采摘效率。彈指式紅棗收獲機(jī)械的研究,就是針對(duì)疆內(nèi)紅棗的采摘要求自主研發(fā)的采摘機(jī)械,紅棗的機(jī)械化收獲對(duì)提高收獲效率, 降低收獲作業(yè)成本, 做到適時(shí)收獲, 提高采凈率都有很大的幫助。1.2國(guó)內(nèi)外現(xiàn)狀及分析根據(jù)全國(guó)各地調(diào)查資料顯示,目前我國(guó)的水果機(jī)械化還只是停留在節(jié)水滴灌、灌溉施肥一體化、包裝保鮮等有限的幾個(gè)工序上,在清洗、分級(jí)中偶有使用,而水果采摘機(jī)械還是很少。我國(guó)的水果采摘機(jī)械種類很少,大型的機(jī)械化設(shè)備使用率很低,只有少量的半自動(dòng)機(jī)械在使用。到本世紀(jì)初,我們國(guó)家雖然紅棗的種類很多,種植面積大。但是對(duì)于機(jī)械化采摘紅棗的技術(shù)還是比較少,機(jī)械化作業(yè)水平很低,需要注入新的采摘機(jī)械。農(nóng)墾科學(xué)院機(jī)械裝備研究所研制的紅棗收獲機(jī)。這是首臺(tái)用于紅棗采摘的收獲機(jī)。該機(jī)全稱是“4YS24紅棗收獲機(jī)”,使用東方紅400型拖拉機(jī)驅(qū)動(dòng);機(jī)械手臂在液壓控制操作下,可以上下、左右、前后、高低靈活運(yùn)動(dòng),準(zhǔn)確地鉗住紅棗樹干并進(jìn)行低頻振動(dòng)。大型的采摘機(jī)械多為震搖式,震搖式采摘采摘時(shí)沒(méi)有選擇性,容易把樹枝樹葉等搖落,不適用于采摘高大的紅棗樹1。 國(guó)外對(duì)水果機(jī)械化收獲技術(shù)的研究較多,機(jī)械采收在美國(guó)、西班牙、俄羅斯、意大利、英國(guó)、德國(guó)、丹麥、匈牙利等國(guó)家的果園應(yīng)用較為普遍。目前, 機(jī)采量較大的果樹作物有蘋果、葡萄、甜橙、桃、李、杏、櫻桃、越桔、油橄欖、核桃、扁桃等。他們采用的機(jī)械收獲方法主要有:震搖法、梳刷法、撞擊法、水力法、半機(jī)械化采收等方法2。但是,針對(duì)紅棗收獲的采摘機(jī)械比較少。對(duì)于紅棗撿拾機(jī)可以參考打瓜的撿拾裝置3。國(guó)外的打瓜撿拾裝置的結(jié)構(gòu)主要有幾種,一種是根據(jù)打瓜長(zhǎng)度設(shè)計(jì)的臂架結(jié)構(gòu)的收割撿拾器,前進(jìn)作業(yè)時(shí)上下浮動(dòng)將打瓜從地上檢起,進(jìn)人輸送裝置;第二種是圓盤狀的結(jié)構(gòu),根據(jù)打瓜的大小在圓盤兩側(cè)加裝斜凸出的擋板,在工作時(shí)利用擋板和圓盤轉(zhuǎn)動(dòng)的慣性力將打瓜撿拾起;另外一種結(jié)構(gòu)是一種圓筒型式的撿拾裝置,根據(jù)打瓜的大小在圓筒外壁上加裝幾塊板狀或棍狀的挑撥齒結(jié)構(gòu),工作時(shí),圓筒旋轉(zhuǎn),附帶著挑撥齒做圓周運(yùn)動(dòng),靠慣性力將打瓜撿拾起來(lái)送人輸送裝置,同這兩種結(jié)構(gòu)相似之處是根據(jù)打瓜大小設(shè)計(jì)的圓筒型結(jié)構(gòu)內(nèi)凹的裝置。在后期的發(fā)展中,撿拾裝置的結(jié)構(gòu)由原來(lái)的檔板式的撿拾板改進(jìn)為柵欄狀的結(jié)構(gòu),靠撿拾輥和擋板撿拾打瓜4。國(guó)內(nèi)的打瓜撿拾裝置的結(jié)構(gòu),一種是機(jī)架中部的滾筒上均布設(shè)置拾瓜裝置;另一種是在撿拾輥上均布扎瓜齒型結(jié)構(gòu),打瓜撿拾起來(lái)之后由后面的瓜齒分離器將打瓜和齒輥分開,打瓜進(jìn)入輸送裝置。從結(jié)構(gòu)上分析,打瓜機(jī)結(jié)構(gòu)由靠慣性力撿拾的刮板型和夾持型向檢拾輥上加裝扎瓜齒型發(fā)展,由于扎瓜齒能夠?qū)⒐侠卫卧?。1.3國(guó)內(nèi)外紅棗撿拾機(jī)械的存在的問(wèn)題首先,現(xiàn)在國(guó)內(nèi)的紅棗收獲機(jī)暫還在發(fā)展階段,把紅棗從棗樹上震搖下來(lái)現(xiàn)在可以實(shí)現(xiàn)機(jī)械作業(yè),但是在紅棗落地以后主要還是依靠人工撿拾,這樣的不利因素是在人工緊缺的時(shí)候紅棗不能及時(shí)收獲入庫(kù)并進(jìn)行加工,會(huì)造成果品品質(zhì)大幅下降,造成不必要的經(jīng)濟(jì)損失。其次,紅棗撿拾機(jī)械不同于打瓜撿拾機(jī)械,打瓜撿拾對(duì)于打瓜表面由機(jī)械造成的傷害沒(méi)有要求,而紅棗在撿拾過(guò)程中應(yīng)該將機(jī)械損傷將為零,所以不能采取扎取式進(jìn)行撿拾。為了減小收獲對(duì)紅棗的機(jī)械損傷,應(yīng)該采取彈指式撿拾收獲。彈指式是仿照人的指頭進(jìn)行作業(yè),不會(huì)對(duì)紅棗造成機(jī)械損傷6。因此本文針對(duì)上述問(wèn)題,設(shè)計(jì)彈指式紅棗撿拾機(jī),即可以降低勞動(dòng)力的投入,解放人力資源。已達(dá)到再投入降低的同時(shí),讓紅棗的產(chǎn)值達(dá)到最大化的目的。1.4研究的內(nèi)容和方法根據(jù)我國(guó)紅棗收獲機(jī)械的發(fā)展現(xiàn)狀和存在的問(wèn)題以及種植戶的更高要求,設(shè)計(jì)出一款實(shí)用性很強(qiáng)的彈指式紅棗撿拾機(jī)。設(shè)計(jì)彈指式紅棗撿拾機(jī)的整體結(jié)構(gòu),主要由動(dòng)力源、傳動(dòng)裝置、彈指式撿拾裝置、裝載裝置、行走膠輪、雜物清理裝置等組成。拖拉機(jī)提供動(dòng)力,通過(guò)聯(lián)軸器與減速器連接,為撿拾裝置提供動(dòng)力。2彈指式紅棗撿拾機(jī)的結(jié)構(gòu)設(shè)計(jì)2.1總體設(shè)計(jì)方案彈指式紅棗撿拾機(jī)的設(shè)計(jì)需要充分發(fā)揮機(jī)械的特性,最大限度的利用機(jī)械結(jié)構(gòu)對(duì)紅棗進(jìn)行采集并且保證收獲的紅棗質(zhì)量和采凈率。機(jī)械化收獲是整個(gè)生產(chǎn)環(huán)節(jié)里的重要部分。所以紅棗采集的技術(shù)的研究是刻不容緩。根據(jù)網(wǎng)上信息的搜索,結(jié)合實(shí)際情況本機(jī)械的基本要求是:減少對(duì)果實(shí)的機(jī)械損傷;提高采集裝置承接的效率;傳動(dòng)裝置要配套和采摘機(jī)械相互協(xié)調(diào)。紅棗撿拾機(jī)模型如下圖:圖2-1 紅棗撿拾機(jī)模型工作原理:該彈指式紅棗撿拾機(jī)其掛在拖拉機(jī)前配重處,拖拉機(jī)推動(dòng)其前進(jìn),地輪帶動(dòng)撿拾棍轉(zhuǎn)動(dòng),撿拾棍上的是彈指對(duì)地上的紅棗施加力,紅棗由于力的作用彈入撿拾機(jī)機(jī)殼內(nèi),進(jìn)入機(jī)殼內(nèi)的半圓槽體后,由絞龍將紅棗持續(xù)輸入到槽體左側(cè),由槽體的漏口出進(jìn)入紅棗送裝置,該輸送裝置為刮板式輸送器,最終通過(guò)輸送裝置將紅棗輸送至紅棗的盛放車斗內(nèi),至此完成紅棗的撿拾。2.2各個(gè)主要部件的結(jié)構(gòu)示意圖及其功能2.2.1彈指式撿拾器圖2-2 彈指式撿拾器正視圖圖2-3 彈指式撿拾器左視圖該裝置為彈指式撿拾器,它的工作原理為由地輪傳動(dòng)為其提供動(dòng)力,其轉(zhuǎn)動(dòng)方向與地輪轉(zhuǎn)動(dòng)方向一致,工作時(shí)彈指會(huì)有一定得入土深度,利用彈指的彈性勢(shì)能將紅棗彈起并進(jìn)入撿拾機(jī)的殼體內(nèi)。2.2.2側(cè)向傳輸裝置圖2-4 側(cè)向傳輸裝置該裝置為螺旋推送裝置,其工作原理為旋轉(zhuǎn)的螺旋葉片將物料推移而進(jìn)行螺旋輸送機(jī)輸送,使物料不與螺旋輸送機(jī)葉片一起旋轉(zhuǎn)的力是物料自身重量和螺旋輸送機(jī)機(jī)殼對(duì)物料的摩擦阻力。2.2.3刮板式輸送器圖2-5 刮板式輸送器刮板式輸送器輸送時(shí)紅棗從下端送入,由回旋的刮板將物料刮送升運(yùn),在外殼上端經(jīng)排料口卸下紅棗。卸下的紅棗最終進(jìn)入車斗內(nèi)。2.2.4地輪圖2-6 撿拾器地輪上圖為彈指式紅棗撿拾機(jī)的地輪,它的功能為支撐整個(gè)機(jī)器。其次還可以起到仿形裝置的作用,解決田間地勢(shì)不平的問(wèn)題。2.2動(dòng)力的選擇該撿拾機(jī)械是與拖拉機(jī)進(jìn)行配套,將撿拾機(jī)械配合于拖拉機(jī)的前配重插孔處7。撿拾動(dòng)力來(lái)源于地輪傳動(dòng),當(dāng)拖拉機(jī)前進(jìn)時(shí)推動(dòng)彈指式紅棗撿拾機(jī)前進(jìn),地輪也隨之轉(zhuǎn)動(dòng),動(dòng)力的大小是由拖拉機(jī)推動(dòng)彈指式紅棗撿拾機(jī)在田間的行使速度決定的,地輪的轉(zhuǎn)速高,帶動(dòng)的撿拾輥的帶輪也轉(zhuǎn)速高。2.3設(shè)計(jì)要求 (1)由于田間作業(yè)場(chǎng)地的約束,本設(shè)計(jì)應(yīng)該盡量小巧緊湊 (2)各個(gè)零件之間盡量不采用焊接及剛性固定,便于零件的更換及修理(3)制造材料應(yīng)該合理選取,節(jié)約成本(4)機(jī)器操作性要強(qiáng),操作簡(jiǎn)單,便于使用2.4設(shè)計(jì)方案(1)對(duì)機(jī)械傳動(dòng)系統(tǒng)和執(zhí)行機(jī)構(gòu)以及輸送機(jī)構(gòu)進(jìn)行運(yùn)動(dòng)尺寸計(jì)算;(2)根據(jù)田間實(shí)際作業(yè)需要設(shè)定彈指式紅棗撿拾機(jī)的尺寸;(3)進(jìn)行各個(gè)傳動(dòng)軸及齒輪的設(shè)計(jì)計(jì)算;(4)進(jìn)行紅棗傳輸方案的確定。3彈指式紅棗撿拾機(jī)的零件設(shè)計(jì) 3.1 計(jì)算撿拾棍帶輪直徑及轉(zhuǎn)速設(shè)定撿拾機(jī)行駛速度為0.8m/s,地輪直徑為210mm,地輪軸上的帶輪直徑為180mm。地輪連接的皮帶輪與撿拾棍帶輪的傳動(dòng)比為1/3。則地輪周長(zhǎng)為則地輪轉(zhuǎn)速為,即因?yàn)椋鶕?jù)所以則取,則所以,取帶輪直徑為63mm3.2 V帶的選取撿拾棍與地輪傳動(dòng)的連接形式為V帶傳動(dòng)如下圖圖3-1 V帶傳動(dòng)示意圖根據(jù)查表得輪胎與干燥的土路摩擦系數(shù)為0.025-0.035,與沙地的摩擦系數(shù)為0.100-0.300,與濕的土路的摩擦系數(shù)為0.050-0.150。設(shè)彈指式紅棗撿拾裝置與地面的壓力為2000N,根據(jù)現(xiàn)實(shí)情況選取取,則根據(jù)公式 (3-2) 取地輪功率為V帶速度為= (3-3)計(jì)算帶輪功率 (3-4)(由下表得工作情況系數(shù)K=1.1)表3-1 工作情況系數(shù)載荷性質(zhì)工作機(jī)原動(dòng)機(jī)電動(dòng)機(jī)(交流啟動(dòng)、三角啟動(dòng)、直流并勵(lì))、四缸以上的內(nèi)燃機(jī)電動(dòng)機(jī)(聯(lián)機(jī)交流啟動(dòng)、直流復(fù)勵(lì)或串勵(lì))四缸以下的內(nèi)燃機(jī)每工作小時(shí)數(shù)載荷變動(dòng)很小液體攪拌機(jī)、通風(fēng)機(jī)和鼓風(fēng)機(jī)(7.5kW)、離心式水泵和壓縮機(jī)、輕負(fù)載輸送機(jī)16161.01.11.21.11.21.3根據(jù), ,確定選用A型普通v帶3.3 V帶線速度的檢驗(yàn) m/s 合適 (3-5)3.4 計(jì)算中心距及基準(zhǔn)長(zhǎng)度初步選取中心距 (3-6)取360mm符合0.7(D1+ D2)a02(D1+ D2),則帶長(zhǎng)為查表取基準(zhǔn)長(zhǎng)度 則實(shí)際中心距: (3-7),合適3.5計(jì)算A型普通v帶根數(shù) 今 查機(jī)械設(shè)計(jì)基礎(chǔ)表13-3知:為單根V帶的基本額定功率,取0.59kw 查機(jī)械設(shè)計(jì)基礎(chǔ)表13-5知: 為單根V帶額定功率的增量,取0.05 kw 查機(jī)械設(shè)計(jì)基礎(chǔ)表13-2知:長(zhǎng)度系數(shù),取0.91 查機(jī)械設(shè)計(jì)基礎(chǔ)表13-7知:為包角系數(shù),取0.95 ,則v帶取z=1根。3.6求作用在帶輪軸上的壓力表3-2 V帶截面尺寸(GB/T 11544-1997)普通V帶類型節(jié)管/mm頂寬b/mm高度h/mm單位長(zhǎng)度質(zhì)量q/(kg/m)A1113100。12根據(jù)上圖可知q=0.1kg/m,帶所能傳遞的最大有效拉力,當(dāng)考慮離心力的不利影響時(shí),單根帶所需的預(yù)緊力,用代入前式,并考慮包角對(duì)所需預(yù)緊力的影響,可將的計(jì)算式子寫為: S式中:q為v帶單位長(zhǎng)度質(zhì)量,0.12kg /m故由可得3.7計(jì)算帶傳動(dòng)作用在軸上的力(簡(jiǎn)稱壓軸力) 為了設(shè)計(jì)安裝帶輪的軸和軸承,必須確定帶傳動(dòng)作用在軸上的力,如果不考慮帶 兩邊的拉力差,則壓軸力可以近似的按帶的兩邊的預(yù)緊力的合力來(lái)計(jì)算: (3-8)3.8 撿拾裝置帶輪結(jié)構(gòu)參數(shù) 設(shè)計(jì)V帶輪時(shí)應(yīng)滿足的要求有:質(zhì)量小,結(jié)構(gòu)工藝性好,無(wú)過(guò)大的鑄造內(nèi)應(yīng)力,轉(zhuǎn)速高時(shí)要經(jīng)過(guò)平衡,輪槽工作面要精細(xì)加工(表面粗糙度一般為3.2),以減少帶的磨損,各槽的尺寸應(yīng)保持一定的精度,以使載荷分布較為均勻等8-10。依照此要求與地輪相連的動(dòng)輪,其帶輪基準(zhǔn)直徑 d=180mm.因?yàn)榕c電動(dòng)機(jī)相連的主動(dòng)輪和從動(dòng)輪的傳動(dòng)比i=3因此與撿拾輥相連的主動(dòng)輪與從動(dòng)輪的尺寸為其帶輪基準(zhǔn)直徑 d=63mm 3.9撿拾裝置軸與齒輪的計(jì)算圖3-2 絞龍軸與傳送軸之間的齒輪連接3.9.1撿拾棍軸的選擇與計(jì)算軸的選擇:軸的材料為45鋼,調(diào)制處理。圖表3-3 軸的常用材料及主要力學(xué)性能材料及熱處理毛坯直徑mm硬度HBS強(qiáng)度極限/MPa屈服強(qiáng)度/MPa彎曲疲勞極限/MPa應(yīng)用說(shuō)明45正火100170 217600300 275用于較重要的軸,應(yīng)用最廣泛查表得:,其有較好的塑性和適當(dāng)?shù)膹?qiáng)度,可做一般曲軸、轉(zhuǎn)軸等。確定各軸及齒輪轉(zhuǎn)速:根據(jù)地輪轉(zhuǎn)速,則撿拾輥軸轉(zhuǎn)速為計(jì)算各軸輸入功率:,=0.98 為軸承傳動(dòng)效率, 為皮帶傳動(dòng)效率, 初步確定軸端直徑:取系數(shù)c為107,軸的輸入端直徑為,則皮地輪軸的直徑,考慮到鍵槽的影響,軸的直徑增加5%,則取皮帶輪軸的直徑為16mm撿拾輥軸的直徑的,考慮到鍵槽的影響,軸的直徑增加5%,則取齒輪軸的直徑為12mm計(jì)算各軸輸入轉(zhuǎn)矩:地輪軸輸出轉(zhuǎn)矩為皮帶輪軸輸入轉(zhuǎn)矩3.9.2傳送帶軸材質(zhì)的選擇表3-4 軸的常用材料及主要力學(xué)性能材料及熱處理毛坯直徑mm 硬度HBS強(qiáng)度極限/Mpa屈服強(qiáng)度/MPa彎曲疲勞極限/MPa應(yīng)用說(shuō)明45正火100170 217600300275用于較重要的軸,應(yīng)用最廣泛軸的材料為45鋼,正火處理。查表得:,用于較重要的軸,應(yīng)用最為廣泛。3.9.3 確定傳送裝置各軸及齒輪轉(zhuǎn)速根據(jù)地輪轉(zhuǎn)速,則皮帶輪軸轉(zhuǎn)速設(shè)齒輪傳動(dòng)比為1:5 則小齒輪轉(zhuǎn)速為3.9.4 計(jì)算傳輸裝置各軸輸出功率 。 為齒輪傳動(dòng)。3.9.5確定傳送裝置個(gè)軸直徑取系數(shù)c為107,軸的輸入端直徑為,則皮帶輪軸的直徑,考慮到鍵槽的影響,軸的直徑增加5%,則取皮帶輪軸的直徑為10mm。大齒輪軸的直徑的,考慮到鍵槽的影響,軸的直徑增加5%,則取齒輪軸的直徑為29mm。3.9.6計(jì)算傳輸裝置各軸輸入轉(zhuǎn)矩飛輪輸出轉(zhuǎn)矩為小齒輪軸輸入轉(zhuǎn)矩大齒輪軸輸入轉(zhuǎn)矩為:3.9.7傳送裝置齒輪參數(shù)計(jì)算選取模數(shù)為2,壓力角為,小齒輪齒數(shù),大齒輪齒數(shù)小齒輪直徑,小齒輪齒頂圓小齒輪齒底圓小齒輪分度圓直徑mm大齒輪直徑大齒輪齒頂圓大齒輪齒底圓大齒輪分度圓直徑mm3.9.8軸的支點(diǎn)距離和力作用點(diǎn)的確定根據(jù)軸上零件的位置可以確定出軸的支點(diǎn)位置,計(jì)算齒輪受力。 齒輪受力:小齒輪,圓周力 徑向力 法向力 ,則,大齒輪,, ,3.9.9撿拾輥軸的設(shè)計(jì)根據(jù)輸送帶輸出軸的外型尺寸可以可以得到傳動(dòng)軸的直徑,根據(jù)設(shè)計(jì)和安裝的要求軸的尺寸如下:軸長(zhǎng):1250mm.傳動(dòng)軸的結(jié)構(gòu)如圖3-3所示:圖3-3 傳動(dòng)軸軸的材料:軸的材料主要是碳剛和合金剛。由于碳剛比合金剛價(jià)格便宜,對(duì)應(yīng)力集中的敏感性較低,同時(shí)也可以用熱處理或化學(xué)熱處理的辦法提高其耐磨性和抗疲勞強(qiáng)度,所以本設(shè)計(jì)采用45號(hào)剛作為軸的材料11。調(diào)制處理。為了防止軸上零件受力時(shí)發(fā)生沿軸向或周向的相對(duì)運(yùn)動(dòng),軸上零件除了有游動(dòng)或空轉(zhuǎn)的要求者外,都必須進(jìn)行軸向和周向定位,以保證其準(zhǔn)確的工作位置12-13。進(jìn)行校核時(shí),通常只校核軸上承受最大彎矩和扭矩的截面的強(qiáng)度,軸為單向旋轉(zhuǎn),旋轉(zhuǎn)切應(yīng)力為脈動(dòng)循環(huán)變應(yīng)力,取,軸的計(jì)算應(yīng)力 前已選定軸的材料為45鋼,調(diào)質(zhì)處理,查表得, 因此,故強(qiáng)度滿足。軸的彎曲剛度校核計(jì)算按材料力學(xué)公式計(jì)算出軸的撓度y和偏轉(zhuǎn)角撓曲線方程: 載荷作用于懸臂端時(shí),(K為軸的懸臂長(zhǎng)度,mm)軸的彎曲剛度條件為:撓度: 偏轉(zhuǎn)角: y軸的允許撓度,mm,軸的允許偏轉(zhuǎn)角,rad,查書機(jī)械設(shè)計(jì)表15-5 得 mm rad 計(jì)算得 由計(jì)算得 所用軸滿足軸的彎曲剛度要求軸的扭轉(zhuǎn)剛度校核計(jì)算軸的扭轉(zhuǎn)變形用每米長(zhǎng)的扭轉(zhuǎn)角 來(lái)表示。圓軸扭轉(zhuǎn)角 的計(jì)算公式為: 軸的扭轉(zhuǎn)剛度條件為 一般傳動(dòng)軸,許用扭轉(zhuǎn)角根據(jù)上述公式計(jì)算出30mm軸能滿足彎曲剛度要求???結(jié)在為期十六周的畢業(yè)設(shè)計(jì)中,讓我學(xué)到了更多的知識(shí),體會(huì)到了學(xué)以致用的含義。本次設(shè)計(jì)主要是針對(duì)成熟以后的落地紅棗,以機(jī)械化采集代替人工采收,解放人力資源。本次畢業(yè)設(shè)計(jì)是一次難得的理論與實(shí)際結(jié)合的機(jī)會(huì),鍛煉和鞏固了我的諸多能力:1、綜合運(yùn)用機(jī)械設(shè)計(jì)基礎(chǔ)、農(nóng)業(yè)機(jī)械學(xué)等其他專業(yè)課程的知識(shí),進(jìn)行農(nóng)用機(jī)械設(shè)計(jì)訓(xùn)練,使已學(xué)知識(shí)得以鞏固、加深和擴(kuò)展;2、學(xué)習(xí)和掌握農(nóng)用機(jī)械零件、部件、機(jī)械傳動(dòng)及一般機(jī)械的基本設(shè)計(jì)方法和步驟,培養(yǎng)自己的工程設(shè)計(jì)能力和分析問(wèn)題,解決問(wèn)題的能力;3、提高在計(jì)算、制圖、運(yùn)用設(shè)計(jì)資料(手冊(cè)、 圖冊(cè))進(jìn)行經(jīng)驗(yàn)估算及考慮技術(shù)決策等機(jī)械設(shè)計(jì)方面的基本技能。4、能夠使自己熟練的運(yùn)用AUTOCAD以及SolidWorks兩種制圖軟件,通過(guò)電腦輔助,使自己的畢業(yè)設(shè)計(jì)更加順利的完成。 在設(shè)計(jì)中也出現(xiàn)了很多問(wèn)題,學(xué)習(xí)是一個(gè)不斷發(fā)現(xiàn)問(wèn)題和不斷解決問(wèn)題的過(guò)程,能夠及時(shí)發(fā)現(xiàn)問(wèn)題并且通過(guò)老師和同學(xué)的幫助去解決問(wèn)題。雖然畢業(yè)設(shè)計(jì)內(nèi)容繁多,過(guò)程繁瑣但我的收獲卻更加豐富。各種系統(tǒng)的適用條件,各種設(shè)備的選用標(biāo)準(zhǔn),各種構(gòu)件的安裝方式,我都是隨著設(shè)計(jì)的不斷深入而不斷熟悉并學(xué)會(huì)應(yīng)用的。和老師的溝通交流更使我對(duì)設(shè)計(jì)有了新的認(rèn)識(shí)也對(duì)自己提出了新的要求。時(shí)間過(guò)的很快,畢業(yè)設(shè)計(jì)馬上就要結(jié)束了,通過(guò)這段時(shí)間的努力,設(shè)計(jì)順利的完成,從中還學(xué)到大量的知識(shí),我相信在以后的學(xué)習(xí)和工作當(dāng)中肯定會(huì)應(yīng)用的到。致 謝本次畢業(yè)設(shè)計(jì)的完成,是在我的導(dǎo)師范修文老師的細(xì)心指導(dǎo)下進(jìn)行的。在每次設(shè)計(jì)遇到問(wèn)題時(shí)范老師不辭辛苦的講解才使得我的設(shè)計(jì)順利的進(jìn)行。從設(shè)計(jì)的選題到資料的搜集再到本畢業(yè)設(shè)計(jì)的編寫、修改,每一步都有范老師的細(xì)心指導(dǎo)和認(rèn)真的解析,花費(fèi)了范老師很多的寶貴時(shí)間和精力,在此向?qū)煴硎局孕牡馗兄x!導(dǎo)師嚴(yán)謹(jǐn)?shù)闹螌W(xué)態(tài)度,開拓進(jìn)取的精神和高度的責(zé)任心都將使我在今后的工作和學(xué)習(xí)中受益匪淺! 感謝我的同學(xué)和朋友,在我寫論文的過(guò)程中給予我了很多素材,還在說(shuō)明書的撰寫和排版過(guò)程中提供熱情的幫助。本次畢業(yè)設(shè)計(jì)的順利完成離不開老師和同學(xué)的協(xié)助指導(dǎo),在我的設(shè)計(jì)過(guò)程中他們都對(duì)我提出了很多寶貴的建議,借此機(jī)會(huì),對(duì)他們熱心而無(wú)私的幫助表示衷心的感謝由于我的學(xué)術(shù)水平有限,所寫設(shè)計(jì)與說(shuō)明書難免有不足之處,懇請(qǐng)各位老師和同學(xué)批評(píng)和指正!參考文獻(xiàn)1 王貴忠.籽瓜撿拾裝置的設(shè)計(jì)J.機(jī)械研究與應(yīng)用,2012,04:148-150.2 吳崇友,丁為民,石磊,張敏.油菜撿拾收獲機(jī)齒帶式撿拾器運(yùn)動(dòng)學(xué)分析J.中國(guó)農(nóng)機(jī) 化,2012,04:68-70. 3 陳度,杜小強(qiáng),王書茂,張勤.振動(dòng)式果品收獲技術(shù)機(jī)理分析及研究進(jìn)展J.農(nóng)業(yè)工程 學(xué)報(bào),2011,08:195-200.4 盛凱,曾南宏,程凱吉林工學(xué)院.彈齒滾筒撿拾器的機(jī)構(gòu)設(shè)計(jì)的解析方法J.吉林工學(xué)院 學(xué)報(bào),1990,02:50-57.5 鄧玉珍.4YS-24型紅棗收獲機(jī)J.農(nóng)業(yè)機(jī)械,2010,03:89.6 湯智輝,沈從舉,孟祥金,賈首星,周艷,鄭炫.4YS-24型紅棗收獲機(jī)的研制J. 農(nóng)機(jī)化,2010,01:30-32.7 湯智輝,賈首星,沈從舉等兵團(tuán)林果業(yè)機(jī)械化現(xiàn)狀與發(fā)展J農(nóng)機(jī)化研究, 2008(11):5-88 梁鴻.中國(guó)紅棗及紅棗產(chǎn)業(yè)的發(fā)展現(xiàn)狀、存在問(wèn)題和對(duì)策的研究D.西安:陜西師范大學(xué), 20069 郭曉成,李倩娥.棗樹栽培新技術(shù)M.陜西楊凌:西北農(nóng)林科技大學(xué)出版社,2005.10 沈瑞珍,俞國(guó)勝.樟子松球果采集機(jī)具的研究J.北京林業(yè)學(xué)院學(xué)報(bào),1990,12(增1): 40-48.11 湯智輝,賈首星,沈從舉等.VIBROLIV干果采收機(jī)的引進(jìn)與試驗(yàn)J,農(nóng)機(jī)化, 2009,(4):38-40.12 姚勇軍.林果業(yè)的發(fā)展優(yōu)勢(shì)整合研究J.大學(xué)學(xué)報(bào),2007,35(2),10-14.13 周莉蓉,翟惠玲.加強(qiáng)紅棗流通的合理化建議J.農(nóng)業(yè)科技與信息,2007,(11):40-42.19 2009年第5期 農(nóng)機(jī)化 國(guó)外農(nóng)機(jī):一 約翰迪爾7760自走式可打包棉花收獲機(jī) 約翰迪爾7760自走式可打包棉花收獲機(jī)是由 美國(guó)迪爾公司于2007年推出的世界上最先進(jìn)的新 一代自走式摘棉機(jī),由一臺(tái)摘棉機(jī)和一臺(tái)機(jī)載的圓 形棉花打包機(jī)組成。它的誕生體現(xiàn)了迪爾公司在棉 花收獲機(jī)械技術(shù)上的世界領(lǐng)先地位,實(shí)現(xiàn)了機(jī)械收 獲棉花的一次革命,即田問(wèn)采棉和機(jī)載打包一次完 成,實(shí)現(xiàn)連續(xù)不問(wèn)斷的田間采棉作業(yè)。該機(jī)具有的 主要特點(diǎn): 1 進(jìn)行連續(xù)不停頓的田間采摘收獲作業(yè) 7760棉花收獲機(jī)柴油箱容積1 136 L,摘錠清 洗液箱容積1 363 L,采棉頭潤(rùn)滑脂箱容積303 L。 每天加注一次液體可以在田間連續(xù)采棉作業(yè)12 h 以上。 據(jù)美國(guó)農(nóng)場(chǎng)主經(jīng)過(guò)2008年棉花采摘季節(jié)的實(shí) 踐,與傳統(tǒng)的棉箱式摘棉機(jī)相比,相同作業(yè)面積時(shí), 7760棉花收獲機(jī)在采摘作業(yè)時(shí)間上平均可以節(jié)約 20-30,大幅度提高了棉花采摘效率。當(dāng)用時(shí)間 作為衡量棉花采摘作業(yè)的要素時(shí),這種效率的提高 無(wú)異是幫助摘棉機(jī)用戶節(jié)約了費(fèi)用。 2 節(jié)約了田間采摘作業(yè)時(shí)需要的人力和相 關(guān)配套的設(shè)備 在采摘作業(yè)中,該機(jī)只需要把機(jī)載的圓形棉花 打包機(jī)彈出的棉花包放置在機(jī)器后面的一個(gè)可升降 的托架上,繼續(xù)進(jìn)行采摘作業(yè)。等該機(jī)到地邊時(shí),直 接把棉包卸載到地面上。僅需要配備一個(gè)拖拉機(jī)后 置式的棉包叉車和一輛棉包運(yùn)輸車。減少了傳統(tǒng)的 棉箱式摘棉機(jī)作業(yè)時(shí)必須配套的運(yùn)棉車、牽引運(yùn)棉 車的拖拉機(jī)或傳統(tǒng)的方形棉花打垛機(jī)等設(shè)備,農(nóng)場(chǎng) 棉機(jī)一樣的摘錠清洗功能,確保了最大的收獲效率。 7 底盤 5 棉花輸送系統(tǒng) 該機(jī)使用了在約翰迪爾自走式摘棉機(jī)上驗(yàn)證多 年的JETAIRTROL棉花輸送系統(tǒng),確保收獲更干 凈的籽棉。 棉花輸送系統(tǒng)由一個(gè)風(fēng)機(jī)和兩個(gè)輸棉管組成, 每個(gè)采棉頭都有一個(gè)單獨(dú)的通向棉箱的輸棉管。即 使在最小動(dòng)力輸出時(shí),該系統(tǒng)也能夠提供出色的籽 棉輸送效率。此外,該系統(tǒng)使采摘頭被阻塞的可能 性降為最低。棉花輸送系統(tǒng)由牽引拖拉機(jī)的后動(dòng)力 輸出軸提供動(dòng)力。 6 棉箱 棉箱容積l3 m3,最大籽棉裝載量約1 000 kg。 棉箱的升起和下降通過(guò)在拖拉機(jī)駕駛室內(nèi)操作液壓 輸出閥手柄完成的。 棉箱系統(tǒng)包含一個(gè)手動(dòng)接合的棉箱油缸鎖。當(dāng) 棉箱在升起并鎖定的情況下,這個(gè)裝置保證了可以 安全地完成各項(xiàng)維修保養(yǎng)工作。 棉箱后部有一個(gè)梯子,棉箱上有安全扶手,為清 理棉箱頂部提供了便利。 該機(jī)在牽引拖拉機(jī)和摘棉機(jī)之間,實(shí)現(xiàn)了可轉(zhuǎn) 向的聯(lián)結(jié)。該裝置允許駕駛員在拖拉機(jī)駕駛室進(jìn)行 道路運(yùn)輸狀態(tài)(正牽引模式)和田間采摘作業(yè)(右置 側(cè)牽引模式)兩種模式下的牽引狀態(tài)轉(zhuǎn)換操作。此 外,該裝置還可以減小轉(zhuǎn)彎半徑。 在道路行走時(shí),使用道路運(yùn)輸牽引模式。這種牽 引模式也被用來(lái)在棉田首次采摘開路時(shí)使用。當(dāng)棉 田采摘通路被打開后,將牽引方式轉(zhuǎn)換成田間采摘 作業(yè)模式,使兩個(gè)采摘頭始終在拖拉機(jī)的右側(cè)工作。 該機(jī)與牽引拖拉機(jī)之間的懸掛連接和分離非常 方便快捷。在從牽引拖拉機(jī)上分離摘棉機(jī)時(shí),駕駛員 先放下停車支架,卸掉動(dòng)力輸出軸,從液壓輸出閥上 拔出液壓管,從拖拉機(jī)后部斷開電線插頭和斷開拖 拉機(jī)牽引桿。三個(gè)人在1 min之內(nèi)就可以完成懸掛 連接或分離。 約翰迪爾7260牽引式摘棉機(jī)在中亞地區(qū)、中國(guó) 已經(jīng)連續(xù)數(shù)年進(jìn)行了田間棉花采摘作業(yè)。實(shí)踐 證明,該機(jī)完全適合在中小規(guī)模棉花種植規(guī)模下對(duì) 棉花機(jī)械化收獲的需求。 (約翰迪爾中國(guó)市場(chǎng)部) 61 國(guó)外農(nóng)機(jī) 農(nóng)機(jī)化 2009年第5期 主明顯減少了在棉花采摘季節(jié)需要雇用的輔助勞動(dòng) 力人數(shù),也減少了在田間需要搬運(yùn)棉花方形打垛機(jī) 的麻煩。 當(dāng)7760棉花收獲機(jī)需要從一塊棉田轉(zhuǎn)移到另 一塊棉田時(shí),可以在1 min之內(nèi)從采摘模式轉(zhuǎn)換到 運(yùn)輸模式,允許駕駛員非常輕松地以27 kmh的速 度在道路上行駛。 不論是摘棉機(jī)在田間采摘棉花,還是從一塊棉 田轉(zhuǎn)移到另一塊棉田,7760棉花收獲機(jī)都把棉花機(jī) 械化收獲提高到了一個(gè)新的水平,創(chuàng)造了一種簡(jiǎn)單 高效的棉花機(jī)械化收獲方式。 3 動(dòng)力強(qiáng)勁,能夠保證在各種條件下棉田 的采摘作業(yè) 約翰迪爾7760自走式可打包棉花收獲機(jī)配備 了約翰迪爾POWERTECH PLu 排氣量135 L、 額定功率370 kW、符合TIER III排放標(biāo)準(zhǔn)的柴油發(fā) 動(dòng)機(jī)。ProDrive 自動(dòng)換檔的變速箱,允許駕駛員在 行進(jìn)時(shí)實(shí)現(xiàn)平穩(wěn)變速。一檔采摘速度可達(dá)68 kmh, 道路運(yùn)輸速度可達(dá)274 kmh。靜液壓四輪驅(qū)動(dòng),保 證強(qiáng)大、高效的驅(qū)動(dòng)能力。適應(yīng)各種條件下棉田的 采摘作業(yè),甚至能夠在泥濘和有積水的棉田中進(jìn)行 采摘作業(yè)。 2008年,美國(guó)路易斯安那州颶風(fēng)災(zāi)害發(fā)生后, 當(dāng)其它型號(hào)自走式摘棉機(jī)都無(wú)法在有積水的棉田中 繼續(xù)采摘作業(yè)時(shí),只有約翰迪爾7760自走式可打包 棉花收獲機(jī)能夠在泥濘的棉田繼續(xù)進(jìn)行采摘作業(yè)。 4 適應(yīng)全天候條件下的采摘作業(yè) 約翰迪爾7760自走式可打包棉花收獲機(jī)的機(jī) 載圓形打包機(jī)把圓形棉包包裹三層,棉包最大直徑 可達(dá)229 m(直徑可調(diào)范圍091229 113),寬度2。43 m,每包籽棉重量2 039-2 265 kg。與傳統(tǒng)的方形棉 花垛相比,網(wǎng)形棉包改善了雨天的防水性能,具有 抗風(fēng)、運(yùn)輸過(guò)程中不易破損等特點(diǎn),圓形棉包的高強(qiáng) 度打包膜從田間到軋花廠的過(guò)程中,很好地保護(hù)了 棉花纖維和棉花種子。 圓形棉包與地面接觸面積小,對(duì)存放場(chǎng)地沒(méi)有 特殊要求,不需要專門的運(yùn)輸車輛。具有拉運(yùn)方便、 在田問(wèn)和軋花廠存放方便的特點(diǎn)。圓形棉花包被全 部包裹,減少了在田問(wèn)和軋花廠存放場(chǎng)地上的籽棉 損失。 62 5 有利于軋花廠的加工 在棉花的收獲和加工季節(jié),對(duì)軋花廠來(lái)說(shuō),籽棉 的運(yùn)輸和存放是非常困難的。圓形棉包具有形狀大 小一致,內(nèi)部濕度恒定和密度均勻,運(yùn)輸和存放靈活 方便的特點(diǎn)。 使用7760棉花收獲機(jī)收獲的棉花,給軋花廠拉 運(yùn)籽棉尤其是在雨天拉運(yùn)籽棉帶來(lái)了極大的便利。 運(yùn)輸圓形棉花包時(shí),首先使用拖拉機(jī)后置式叉 車在田間將棉花包分段運(yùn)輸,再使用標(biāo)準(zhǔn)的方形棉 花垛運(yùn)輸卡車或平板卡車將圓形棉花包運(yùn)走。一輛 標(biāo)準(zhǔn)的方形棉花垛運(yùn)輸卡車每次可以裝運(yùn)四個(gè)圓形 棉花包,長(zhǎng)1464 in的平板卡車一次可以裝載6個(gè) 圓形棉花包,1617 m的平板卡車一次可以裝載7 個(gè)圓形棉花包。 圓形棉花包被全部包裹,從田間到軋花廠包中 的籽棉幾乎不損失。在加工圓形棉花包時(shí),由于圓形 棉花包不會(huì)在場(chǎng)地上散落棉花,軋花廠也不需要專 門派人來(lái)清理。而傳統(tǒng)的方形棉花垛堆放在軋花廠 場(chǎng)地上會(huì)吸收地上的水分并容易受雨水的侵蝕,在 喂人軋花加工線前,需要烘干處理、把臟棉花人工分 撿出來(lái)。而全包裹的圓形棉花包從田間到軋花廠的 場(chǎng)院、軋花加工線一直能保持籽棉的干燥。 圓形棉花包中的含水量恒定在大約85,因此 棉花烘干需求的爐溫低、時(shí)間短,所以軋花加工線每 小時(shí)大約平均可以增加7包的喂入量。此外,由于圓 形棉花包里的籽棉靜電減少了,所以在軋花加工線 上喂入來(lái)自圓形棉花包中的籽棉時(shí),要比喂人方形 棉花垛中的籽棉更容易了。據(jù)美國(guó)德克薩斯州的一 個(gè)軋花廠測(cè)算,在2008年秋季發(fā)生颶風(fēng)期間,他們 在雨天加工圓形的棉花包時(shí),節(jié)省了40的用于烘 干籽棉的燃料。另外,圓形棉花包的包裝膜完全可以 回收再利用,也成為了軋花廠的一筆額外收人。 經(jīng)過(guò)美國(guó)2008年棉花收獲季節(jié)的實(shí)踐,約翰迪 爾7760自走式可打包棉花收獲機(jī)得到了棉花農(nóng)場(chǎng) 主和軋花廠的普遍好評(píng)。該機(jī)不僅實(shí)現(xiàn)了田間連續(xù) 不停頓的采摘作業(yè),使農(nóng)場(chǎng)主提高了棉花收獲的采 摘效率。而且,緊湊的圓形棉花包幫助軋花廠減少了 籽棉的損失和棉花等級(jí)的降低,也為軋花廠提供了 籽棉拉運(yùn)和存放的靈活性和方便性,并提高了軋花 加工線的加工效率。 (約翰迪爾中國(guó)市場(chǎng)部) 2950 Niles Road, StJosepli _ 49085-9659, USA 269.429-0300 fax 26S.4293SS2 hc|#asabe.org www.asabe.orgAn 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 iutterasabe.org 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 9兩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 hav
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