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XX大學(xué)
畢業(yè)論文（設(shè)計(jì)）綜合成績?cè)u(píng)定表
學(xué)生姓名
班級(jí)
論文（設(shè)計(jì)）題目
組合式棉稈收獲機(jī)的設(shè)計(jì)
評(píng)定項(xiàng)目
指導(dǎo)教師評(píng)分
（20%）
評(píng)閱教師評(píng)分
（20%）
答辯小組評(píng)分
（60%）
原始得分
（百分制）
85
86
76
按評(píng)分比例
折合得分
17
17.2
45.6
總分
79.8
等級(jí)
評(píng)定
根據(jù)指導(dǎo)教師、評(píng)閱教師、答辯專家組評(píng)審意見，經(jīng)綜合評(píng)定，該生畢業(yè)論文（設(shè)計(jì)）的等級(jí)為：
學(xué)院答辯委員會(huì)負(fù)責(zé)人（簽字）：
年 月 日
16屆畢業(yè)設(shè)計(jì)
組合式棉稈收獲機(jī)的設(shè)計(jì)
學(xué)生姓名 ____________
學(xué) 號(hào) ______
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) _________
指導(dǎo)老師 __________
日 期 ________
機(jī)械電氣化工程學(xué)院制
前 言
棉花是主要的經(jīng)濟(jì)作物之一，大部分棉稈采用粉碎還田方式處理，只有少部分進(jìn)行再利用。主要因?yàn)橐环矫婷迼U粉碎還田，可補(bǔ)充和更新土壤有機(jī)質(zhì)等養(yǎng)分，保持土壤水分和改善土壤物理性狀。
從國內(nèi)外目前棉稈收獲機(jī)械現(xiàn)狀來看，國內(nèi)有多家機(jī)構(gòu)在積極探求新的棉稈收獲機(jī)械型式，但大多機(jī)型適應(yīng)性較差、機(jī)械故障率高，可靠性差，難以進(jìn)行大面積推廣,且對(duì)收獲裝置的工作參數(shù)也缺乏系統(tǒng)的專門研究，以致于收獲效果不是很理想。棉稈機(jī)械化收獲目前常采用的方式主要有剪切收獲和提拔式收獲兩種。剪切收獲，主要是利用割刀將棉稈從根部割斷，此種收獲方式不能實(shí)現(xiàn)棉稈的全部收獲，造成資源浪費(fèi)，另外由于棉稈根莖較硬不易腐爛、不易粉碎，在土壤里留存時(shí)間較長，不利于后續(xù)整地作業(yè)和農(nóng)作物生長。此外棉花種植過程中地膜的使用，造成土壤白色污染日益嚴(yán)重。通過對(duì)殘膜回收機(jī)田間作業(yè)情況進(jìn)行調(diào)查，結(jié)果表明棉稈及棉根對(duì)殘膜回收機(jī)的作用效果有著嚴(yán)重的影響。依據(jù)現(xiàn)有國內(nèi)棉稈收獲經(jīng)驗(yàn)，為解決棉稈可靠拔取與輸送問題，提出了一種新的拔取輸送方式，提輥裝置與拔稈齒輥相結(jié)合的組合方式。該裝置主要包括機(jī)架、提輥裝置、拔稈齒輥裝置。主要工作過程是提輥裝置進(jìn)行土層淺層的翻攪，拔稈齒輥裝置與提輥裝置配合進(jìn)行棉稈的拔取與輸送。該方式一方面能有效拔取棉稈，降低功耗，加快莖稈向后輸送。另一方面增加了棉稈收獲機(jī)械的田間適應(yīng)性。后懸掛加置了殘膜回收裝置，大大減少了田間白色污染。
關(guān)鍵詞 ：棉稈；拔稈收膜；高效
目錄
1緒論 1
1.1課題背景 1
1.2研究的目的和意義 1
1.3國內(nèi)外棉花拔稈收膜機(jī)的發(fā)展?fàn)顩r 1
2本課題需要重點(diǎn)研究的關(guān)鍵的問題及解決的思路 6
2.1棉花種植情況 6
2.2棉花阻力分析 6
2.3機(jī)械設(shè)計(jì)遇到的問題 7
3總體方案設(shè)計(jì) 7
3.1設(shè)計(jì)任務(wù) 7
3.2基本要求 7
3.3注意事項(xiàng) 7
3.4機(jī)構(gòu)選型原則 8
4組合式棉稈收獲機(jī)的機(jī)構(gòu)設(shè)計(jì) 8
4.1 組合式棉稈收獲機(jī)的基本結(jié)構(gòu)如圖4-1所示 8
4.2組合棉稈收獲機(jī)的工作原理 9
4.3提輥裝置的設(shè)計(jì) 9
4.4撥禾輪的設(shè)計(jì) 9
4.5傳送裝置的設(shè)計(jì) 10
5組合式棉花拔稈機(jī)的設(shè)計(jì)計(jì)算與校核 10
5.1電動(dòng)機(jī)的選擇 10
5.2提輥裝置拔棉稈的阻力分析 11
5.3撥禾輪運(yùn)動(dòng)軌跡分析 13
5.4傳送帶的設(shè)計(jì)計(jì)算 15
總 結(jié) 16
致 謝 17
參考文獻(xiàn) 18
畢業(yè)設(shè)計(jì)
1 緒論
1.1 課題背景
農(nóng)業(yè)生物質(zhì)能產(chǎn)業(yè)的發(fā)展為農(nóng)業(yè)提供了一個(gè)產(chǎn)品附加值高和市場潛力大的平臺(tái)。棉花是主要的經(jīng)濟(jì)作物之一，大部分棉稈采用粉碎還田方式處理，只有少部分進(jìn)行再利用。棉花秸稈是棉花的主要副產(chǎn)品,也是工農(nóng)業(yè)的重要生物資源,棉花秸稈收獲裝備對(duì)實(shí)現(xiàn)棉花秸稈的資源化和商品化至為關(guān)鍵，與此棉花的種植還有地膜的使用，這就使的在棉花收獲后會(huì)有棉稈收獲和殘膜收回問題。本項(xiàng)目擬針對(duì)現(xiàn)有拔稈式收獲機(jī)械存在的問題進(jìn)行分析，提出一種組合式棉稈拔取收獲裝置，進(jìn)行樣機(jī)設(shè)計(jì)及制造、田間試驗(yàn)并對(duì)該裝置的作用機(jī)理進(jìn)行研究，研究棉稈生物特性參數(shù)、土壤物理特性、兩種裝置動(dòng)力學(xué)參數(shù)對(duì)于收獲作業(yè)質(zhì)量的影響機(jī)理，構(gòu)建該裝置收獲作業(yè)數(shù)學(xué)模型，綜合分析影響機(jī)械收獲效果的多因素關(guān)系。本研究將為棉稈收獲技術(shù)與裝備的研發(fā)提供理論基礎(chǔ)和新方法[1]。
1.2 研究的目的和意義
棉花秸稈是棉花的主要副產(chǎn)品,也是工農(nóng)業(yè)的重要生物資源,棉花秸稈收獲裝備對(duì)實(shí)現(xiàn)棉花秸稈的資源化和商品化至為關(guān)鍵。我國農(nóng)業(yè)生物質(zhì)能資源主要包括農(nóng)作物秸稈、畜禽糞便、農(nóng)產(chǎn)品加工副產(chǎn)品和能源作物等，其中農(nóng)作物秸稈和能源作物秸稈有著非常廣泛的用途。棉稈可用于生產(chǎn)人造纖維、刨花板、吸音板等板材和造紙；還可通過生物質(zhì)能的轉(zhuǎn)化技術(shù)，將棉稈轉(zhuǎn)化成木炭、可燃?xì)怏w或電力；另外，棉稈還具有很高的營養(yǎng)價(jià)值，可作為很好的畜類動(dòng)物飼料[2]。由此可見，棉稈資源豐富，是一種利用價(jià)值很高的農(nóng)業(yè)生物質(zhì)能。
棉稈機(jī)械化收獲目前常采用的方式主要有剪切收獲和提拔式收獲兩種。剪切收獲，主要是利用割刀將棉稈從根部割斷，此種收獲方式不能實(shí)現(xiàn)棉稈的全部收獲，造成資源浪費(fèi)，另外由于棉稈根莖較硬不易腐爛、不易粉碎，在土壤里留存時(shí)間較長，不利于后續(xù)整地作業(yè)和農(nóng)作物生長。此外棉花種植過程中地膜的使用，造成土壤白色污染日益嚴(yán)重。通過對(duì)殘膜回收機(jī)田間作業(yè)情況進(jìn)行調(diào)查，結(jié)果表明棉稈及棉根對(duì)殘膜回收機(jī)的作用效果有著嚴(yán)重的影響。拔稈式收獲，具備不留根茬、作業(yè)成本低，有助于殘膜回收等優(yōu)點(diǎn)[3]。因而無論是進(jìn)行棉稈收獲還是秸稈還田，棉稈收獲機(jī)采用拔稈式收獲方法不僅提高了棉稈的利用率，也將大大提高殘膜收凈率。通過對(duì)比各種棉稈收獲裝置優(yōu)缺點(diǎn)及田間適應(yīng)性，提出一種有提輥裝置與拔稈齒輥裝置相結(jié)合的拔稈裝置，有效的解決了拔稈效率和田間適應(yīng)性，拔稈徹底，無殘留，也將大大提高殘膜收回率，提高了田間作業(yè)效率，節(jié)約大量勞動(dòng)力[4]。
1.3國內(nèi)外棉花拔稈收膜機(jī)的發(fā)展?fàn)顩r
國外棉軒收獲技術(shù)研究進(jìn)展及其代表機(jī)型簡述
1）棉軒刨挖技術(shù)
這種技術(shù)釆用對(duì)稱傾斜雙圓盤對(duì)棉軒進(jìn)行刨挖，與雙圓盤開溝器的作業(yè)原理相同，代表機(jī)型為美國的Dave和Orthman棉稈挖刨機(jī)，如圖1-1，1-2所示。其中機(jī)型根據(jù)需要可調(diào)整其收獲棉稈的行數(shù)，其參數(shù)有2、4、6、8行四種，對(duì)不同濕度棉桿有較強(qiáng)的適應(yīng)性。而Orthman機(jī)型的圓盤角度和高度是可調(diào)的，拔軒機(jī)構(gòu)設(shè)計(jì)為可折疊式，采用平行四桿仿形，并在其后面安裝切碎裝置，實(shí)現(xiàn)棉稈的起拔與切碎還田[4]。
圖1-1 Dave Koenig 拔棉稈機(jī)
圖 1-2 Orthman 拔棉稈機(jī)
2） 棉稈拔取技術(shù)
這種技術(shù)采用45°傾角安裝橡膠輪胎對(duì)輯起拔。代表機(jī)型有澳大利亞生產(chǎn)的Muti拔棉桿機(jī)以及美國生產(chǎn)的AMADAS棉稈拔取切碎收獲機(jī)，如圖所1-3，1-4示。這兩種機(jī)型能將棉稈連根拔起并切碎，機(jī)具行走速度快，有較高的穩(wěn)定性且設(shè)有傳動(dòng)安全防護(hù)措施。但該技術(shù)
對(duì)種植行距要求較高，適用于標(biāo)準(zhǔn)化規(guī)?；N植。
圖 1-3 Muti 拔棉稈機(jī)
圖 1-4 AMADAS 高速棉稈切碎收獲機(jī)
國外棉稈拔取收獲機(jī)械基本上以對(duì)輥式起拔裝置為主，以一組間隙可調(diào)、相對(duì)滾動(dòng)的膠輥為拔稈部件，對(duì)行收獲，棉稈拔出直接切斷還田。起拔裝置是棉稈拔稈收獲機(jī)械中最關(guān)鍵的部件，起拔性能的好壞，直接影響整機(jī)的工作性能。一般起拔裝置有齒盤式、鋤鏟式、夾持式、對(duì)輥式、提輥式及齒輥式幾種類型。由于受膠輥結(jié)構(gòu)尺寸的限制，對(duì)于國內(nèi)棉稈的收獲并不適應(yīng)。
目前應(yīng)用較廣泛的棉軒收獲機(jī)械所采用的收獲原理和方法大致可以分為：產(chǎn)切法、滾切法、提拔法三種[5]。
國內(nèi)棉軒收獲技術(shù)研究進(jìn)展及其代表機(jī)型簡述
1）產(chǎn)切法
該方法利用“V”型雙翼刀以一定角度深入土壤下約80mm，由動(dòng)力機(jī)帶動(dòng)產(chǎn)刀將棉根伊斷，并將棉稈向上抬起，再由輸送裝置將其收集成堆。由于刀入土作業(yè)，其前行過程中由前次作業(yè)所帶起的土壤及作物根巷若不能及時(shí)掉落并與辛產(chǎn)刀分離，下次作業(yè)時(shí)伊刀前端就會(huì)大量壅土，不但增加了伊刀工作阻力，致使作業(yè)效率低下，也增加了機(jī)具的功耗。該方法存在動(dòng)力消耗大、殘留棉根較多、鋪放不整齊等缺點(diǎn)。
該方法的典型機(jī)型為4MC-4型綿花稻稈收獲機(jī)，由農(nóng)業(yè)科學(xué)院農(nóng)業(yè)機(jī)械化研究所研制生產(chǎn)，其機(jī)械結(jié)構(gòu)如圖1-5所示。該機(jī)具作業(yè)幅寬為1.8m，作業(yè)速度為7km/h～12km/h，一次可收獲4行棉稈，鏟稈率為96%，集堆率為90%。一次可收獲4行棉稈，鏟稈率為96%，
集堆率為90%。集堆率為90%[6]。
圖1-5 4MC-4型棉稈收獲機(jī)田間作業(yè)
2）滾切法
該方法基于旋耕原理，采用旋轉(zhuǎn)刀棍作為收獲部件進(jìn)行作業(yè)。為便于纟產(chǎn)切提拔，在水平刀棍上等角度安裝三組刀片。機(jī)組在田間作業(yè)時(shí)，隨著機(jī)組前行，刀輥逆向旋轉(zhuǎn)切入棉稈根部，刀片將棉根產(chǎn)斷，并將其拔起。刀棍為通軸刨刀，在整個(gè)作業(yè)過程中機(jī)具無需考慮棉稈行距，且土壤被刀輔不斷翻動(dòng)，棉根被產(chǎn)斷，不會(huì)發(fā)生壅土現(xiàn)象。該方法同樣消耗動(dòng)力較大，但工作效率較高，對(duì)不同棉桿的行距適應(yīng)性較強(qiáng)，主要適應(yīng)于直徑較細(xì)小，高度不超過1m的密植棉桿[7]。
該技術(shù)的典型機(jī)型為4M BOX-1.5型棉花拔稈清膜旋耕機(jī)，由昌吉州農(nóng)牧業(yè)機(jī)械技術(shù)推廣站研制生產(chǎn)，其機(jī)械結(jié)構(gòu)如圖1-6所示。該機(jī)可一次性收獲4行棉稈，不受株距、行距限制，兼具清除回收地膜的功能，作業(yè)速度1.4M/s，棉禾干凈拔率高達(dá)99%[8]。
1.機(jī)架 2.主動(dòng)軸 3.邊側(cè)板 4.滾輪帶齒拔稈波輪5.邊側(cè)板入土開溝器
6.滾刀起拔器 7.摟把器機(jī)架 8.拉筋 9.摟把器拉桿 10.壓簧杠桿鎖死機(jī)構(gòu) 11.摟把器彈齒
圖1-6棉花拔軒清膜旋耕機(jī)結(jié)構(gòu)示意圖
3） 提拔法
該方法利用夾持裝置夾持棉稈，在機(jī)組田間行進(jìn)速度配合下，拉動(dòng)起拔機(jī)構(gòu)產(chǎn)生向上的提拔力，將棉根從土壤中拔出。大部分機(jī)械設(shè)計(jì)有撿拾喂入部分，或設(shè)計(jì)有輸送機(jī)械，可將棉稈直接收集或鋪放在地面上。這類機(jī)具的工作原理、設(shè)計(jì)結(jié)構(gòu)相對(duì)復(fù)雜，制造成本較高，同時(shí)對(duì)棉花種植的株距、行距、機(jī)具在田間的行進(jìn)速度與夾持裝置的配合要求也很高。但該方法動(dòng)力消耗較少，拔凈率較高，殘留棉根較少。
提拔式的棉稈收獲機(jī)按照夾持機(jī)構(gòu)的形狀和結(jié)構(gòu)可分為輯式、鏈桿式與夾式。輯式起拔機(jī)構(gòu)分圓錐輯、半回柱輯、圓柱輯及圓柱圓錐綜合無等；鏈桿式起拔機(jī)構(gòu)分為單鏈桿式、雙鏈桿式、鏈爪式及齒盤鏈桿式等；夾式起拔機(jī)構(gòu)分為鉗夾式、平動(dòng)夾式及盤夾式。
在國內(nèi)對(duì)于棉花秸稈機(jī)械化收獲技術(shù)和裝備的研究主要是借鑒國外技術(shù)集中于對(duì)拔取收獲技術(shù)和裝備進(jìn)行研究，但因季節(jié)變化問題，品種問題，不同地域問題，土壤堅(jiān)實(shí)度，溫度及濕度等對(duì)該方式的棉稈收獲機(jī)械有很大的影響，造成收獲機(jī)械適應(yīng)性差，可靠性不高。雖然拔稈式收獲具備很多優(yōu)點(diǎn)，但目前國內(nèi)棉稈拔稈式收獲裝備技術(shù)落后，對(duì)機(jī)械收獲動(dòng)力學(xué)特性和作業(yè)質(zhì)量產(chǎn)生機(jī)理不明晰，使得我國棉稈收獲機(jī)械難以大面積推廣應(yīng)用[9]。
因此，本項(xiàng)目提出棉稈組合式撥稈收獲裝置的研制，一方面為棉稈高效收獲技術(shù)與裝備的研發(fā)提供一種解決思路及理論基礎(chǔ)。另一方面也有助于提升棉稈收獲效率、降低勞動(dòng)強(qiáng)度、提高棉稈資源化利用水平，長遠(yuǎn)來看，對(duì)于恢復(fù)和穩(wěn)定我國棉花生產(chǎn)具有長遠(yuǎn)的戰(zhàn)略意義。
2 本課題需要重點(diǎn)研究的關(guān)鍵的問題及解決的思路
2.1棉花種植情況
是國家重要的商品棉生產(chǎn)基地，經(jīng)過九五、十五、十一五計(jì)劃的發(fā)展，棉花已基本形成了300萬噸的生產(chǎn)能力。根據(jù)農(nóng)科院的資料，在土壤肥沃，光照充足的地區(qū)，棉花合理密植，每畝株數(shù)以15000株左右為宜。對(duì)于機(jī)采棉，可以采用10cm，66cm的株距和行距。對(duì)于地膜覆蓋，可以采用20cm，60cm的株距和行距。本課題所采用的是3米的寬幅，每次收獲4行，符合大部分地區(qū)，保證棉稈收獲高效進(jìn)行[10]。
2.2棉花阻力分析
棉稈起拔阻力是棉桿收獲研究的重要技術(shù)參數(shù)，也是棉稈收獲機(jī)械設(shè)計(jì)的重要理論依據(jù)。
棉花根系屬直根系，分為主根和側(cè)根，在土壤養(yǎng)分、水分和土質(zhì)合適的情況下，根系生長非常發(fā)達(dá)。棉稈起拔過程中，根系發(fā)生斷裂，土壤產(chǎn)生變形，同時(shí)根系與土壤間還存在點(diǎn)著力和摩擦力，這些因素綜合形成起拔阻力。農(nóng)業(yè)生產(chǎn)實(shí)踐經(jīng)驗(yàn)表明，在相同的起拔條件下，與垂直方向成一夾角、沿傾斜方向起拔棉稈所需的起拔力小于沿垂直方向上的起拔力。山西省運(yùn)城市農(nóng)機(jī)科研所沈新民曾對(duì)棉稈的起拔阻力進(jìn)行了測(cè)定，分析了土壤情況、棉稈生長情況等因素對(duì)拔取力的影響，得出土質(zhì)的不同、土壤干基含水率及土壤堅(jiān)實(shí)度對(duì)棉稈起拔阻力影響較大。
棉稈在田間的生長、起拔示意如圖2-1所示。由圖2-1可知，起拔機(jī)構(gòu)對(duì)棉稈進(jìn)行起拔時(shí)，起拔力F與地面形成夾角α其為水平起拔力與垂直起拔力的合力。沿不同方向起拔時(shí)，棉稈根系斷裂過程、土壤變形過程以及根系與土壤間的粘著力均存在差異，使所需起拔力的大小有所不同。針對(duì)不同土壤條件、不同起拔角度下的棉稈起拔力F進(jìn)行測(cè)量，可以分析上述因素的影響，為棉稈起拔機(jī)械的合理設(shè)計(jì)提供依據(jù)[11]。
1.棉稈主莖 2.起拔裝置
圖2-1 起拔力測(cè)量原理[12]
2.3機(jī)械設(shè)計(jì)遇到的問題
1）提輥裝置、拔稈齒輥裝置組合設(shè)計(jì)。該裝置主要包括機(jī)架、提輥裝置、拔稈齒輥裝置。主要工作過程是提輥裝置進(jìn)行土層淺層的翻攪，拔稈齒輥裝置與提輥裝置配合進(jìn)行棉稈的拔取與輸送。該方式一方面能有效拔取棉稈，降低功耗，加快莖稈向后輸送。
2）該組合裝置如何能高效率，低功耗工作。本項(xiàng)目通過對(duì)莖稈在提輥及拔稈齒輥裝置共同作用下的運(yùn)動(dòng)規(guī)律進(jìn)行分析，建立莖稈的運(yùn)動(dòng)學(xué)方程，結(jié)合高速攝影，分析影響拔取及輸送的主要因素，以整機(jī)消耗功率最小為目標(biāo)函數(shù)，以喂入量、組合裝置的結(jié)構(gòu)參數(shù)及運(yùn)行參數(shù)為約束條件對(duì)各參數(shù)進(jìn)行優(yōu)化，在ADAMS軟件中對(duì)棉稈、樣機(jī)的提拔輸送裝置進(jìn)行建模，以優(yōu)化參數(shù)對(duì)莖稈的運(yùn)動(dòng)進(jìn)行仿真試驗(yàn)，并對(duì)莖稈的軌跡進(jìn)行模擬分析，以尋求最佳拔取輸送參數(shù)值。為設(shè)計(jì)性能優(yōu)良的棉稈收獲機(jī)提供理論依據(jù)。
3 總體方案設(shè)計(jì)
3.1設(shè)計(jì)任務(wù)
1)相關(guān)外文資料翻譯和查找搜集相關(guān)技術(shù)資料
2)撰寫任務(wù)書和開題報(bào)告；
3)根據(jù)給定的技術(shù)參數(shù)，確定機(jī)器的執(zhí)行機(jī)構(gòu)，設(shè)計(jì)機(jī)器整體結(jié)構(gòu)；
4)撰寫設(shè)計(jì)說明書；
5)繪制總裝圖、部裝圖和零件圖。
3.2基本要求
1)結(jié)構(gòu)簡單，制造容易；
2)操作、維護(hù)方便、安全。
3.3注意事項(xiàng)
1)在設(shè)計(jì)開始前，應(yīng)認(rèn)真研究題目，明確設(shè)計(jì)要求，閱讀參考資料，了解它們大體內(nèi)容，以便需要時(shí)查閱；
2)對(duì)設(shè)計(jì)方案及結(jié)構(gòu)，設(shè)計(jì)小組應(yīng)進(jìn)行討論對(duì)比，以明確優(yōu)劣正誤，取長補(bǔ)短，改進(jìn)設(shè)計(jì)；
3)設(shè)計(jì)草圖完成后，應(yīng)交指導(dǎo)教師審查后再修改加深；
4)設(shè)計(jì)說明書應(yīng)按規(guī)定格式編寫，連同所繪圖紙交指導(dǎo)教師審查認(rèn)可后方可呈交；
5)認(rèn)真做好準(zhǔn)備，進(jìn)行設(shè)計(jì)答辯；
3.4機(jī)構(gòu)選型原則
1)滿足需要原則
所設(shè)計(jì)的產(chǎn)品應(yīng)最大限度地滿足用戶要求。應(yīng)在調(diào)查分析和預(yù)測(cè)市場需要情況下的基礎(chǔ)上，確定是否應(yīng)該進(jìn)行該種機(jī)械產(chǎn)品的設(shè)計(jì)。
2)經(jīng)濟(jì)合理原則
所設(shè)計(jì)的機(jī)械產(chǎn)品應(yīng)該機(jī)構(gòu)先進(jìn)，功能好，成本低、使用維修方便，在產(chǎn)品的壽命周期內(nèi)用最低的成本實(shí)現(xiàn)產(chǎn)品規(guī)定功能，做到物美價(jià)廉。
3)可靠性原則
在規(guī)定使用條件和規(guī)定時(shí)間內(nèi)，產(chǎn)品能完成規(guī)定功能的可靠程度高，即運(yùn)行中不出現(xiàn)故障。
4)最優(yōu)化設(shè)計(jì)
在給定的設(shè)計(jì)目標(biāo)下，用優(yōu)化設(shè)計(jì)方法，從若干可行方案中找到優(yōu)選方案。
5)標(biāo)準(zhǔn)化原則
所設(shè)計(jì)的機(jī)械產(chǎn)品規(guī)格參數(shù)應(yīng)符合國家標(biāo)準(zhǔn)，零部件應(yīng)能最大限度地與同類產(chǎn)品的零部件通用。
4組合式棉稈收獲機(jī)的機(jī)構(gòu)設(shè)計(jì)
4.1 組合式棉稈收獲機(jī)的基本結(jié)構(gòu)如下圖
1.提輥傳動(dòng)輪 2.提輥裝置 3.傳送帶軸 4.機(jī)架 5.撥禾輪 6.撥禾齒
7.撥禾傳動(dòng)輪 8.變向電機(jī) 9.懸掛 11.傳送帶傳動(dòng)輪 12.傳送帶 13.地輪 14.提輥刀齒
圖 4-1 棉稈收獲機(jī)的裝配圖
4.2組合棉稈收獲機(jī)的工作原理
提輥裝置與撥禾輪相連，由此提供動(dòng)力，提輥式拔棉稈是采用旋切原理,使提輥刀具在地表下一定深度旋切土壤,同時(shí)將棉稈從根部旋切拔出，同時(shí)撥禾輪彎齒抓取棉稈，由于棉稈冠較大，會(huì)卡在倆彎齒之間，棉稈隨彎齒運(yùn)動(dòng)到橫向傳送帶時(shí)，由于重力作用落下，由傳送帶傳出。
4.3提輥裝置的設(shè)計(jì)
1.輥軸2.刀片
圖4-2 提輥裝置
提輥式拔棉稈是采用旋切原理,使提輥刀具在地表下一定深度旋切土壤,同時(shí)將棉稈從根部旋切拔出。旋切刀具模型如圖4-2所示。在旋切過程中,提輥刀要對(duì)土壤和棉根進(jìn)行切削,同時(shí)由于提輥刀具的旋轉(zhuǎn)作用,還會(huì)將切削下的土壤向后拋送。
4.4撥禾輪的設(shè)計(jì)
1. 五星輪2.彎齒軸
圖4-3 拔稈齒輥
撥禾輪是此設(shè)備的主要部件，主要承擔(dān)提取棉稈放到傳送帶上。采用11根彎齒，每根彎齒間距20公分，可實(shí)現(xiàn)任意位置拔取，任意行距，無需調(diào)整機(jī)具對(duì)準(zhǔn)棉稈行距，實(shí)現(xiàn)快速拔稈，高效率工作。次撥禾輪齒采取微彎曲處理，保證抓取棉稈。而且撥禾輪齒向左傾斜，使棉稈運(yùn)行到傳送帶上方時(shí)，由于重力作用方便下落，保證棉稈拔取高效進(jìn)行。
4.5傳送裝置的設(shè)計(jì)
1.傳動(dòng)軸 2.傳送帶
圖 4-4傳送帶
傳送裝置是起到方便收獲的作用，因?yàn)槊薅挵稳『笊⒙湟坏?，?duì)于后面的集中成捆運(yùn)輸不便，首先收獲量太大，所以傳送裝置安置在滾軸下面，由傳送帶直接將拔取的棉稈傳送至一邊，便于集中打捆。以此，大大減少了勞動(dòng)力，提高了效率。
5 組合式棉花拔稈機(jī)的設(shè)計(jì)計(jì)算與校核
5.1電動(dòng)機(jī)的選擇
根據(jù)資料得主軸的轉(zhuǎn)速在 800-1000 轉(zhuǎn)/分，按《機(jī)械設(shè)計(jì)實(shí)用手冊(cè)》推薦的傳動(dòng)比合理取值范圍，取 V 帶的傳動(dòng)比 圖即可滿足電動(dòng)機(jī)的轉(zhuǎn)速與主軸的轉(zhuǎn)速相匹配。由《機(jī)械設(shè)計(jì)課程設(shè)計(jì)手冊(cè)》綜臺(tái)考慮電動(dòng)機(jī)和傳動(dòng)裝置的尺寸 、重量以及帶傳動(dòng)的傳動(dòng)比，選定電動(dòng)機(jī)型號(hào)為Y100L。所選電動(dòng)機(jī)的額定功率 P=1.5kw滿載轉(zhuǎn)速n=800r/min，總傳動(dòng)比適中，傳動(dòng)裝置結(jié)構(gòu)較緊湊。
Y100L-6主要參數(shù)如下表
電動(dòng)機(jī)型號(hào)
額定功率/kw
滿載轉(zhuǎn)速/（r/min）
堵轉(zhuǎn)轉(zhuǎn)矩
最大轉(zhuǎn)矩
質(zhì)量/kg
Y100L
1.5
800
2.0
2.0
32
5.2提輥裝置拔棉稈的阻力分析
提輥式拔棉稈是采用旋切原理,使提輥刀具在地表下一定深度旋切土壤,同時(shí)將棉稈從根部旋切拔出。在旋切過程中,提輥刀要對(duì)土壤和棉根進(jìn)行切削,同時(shí)由于提輥刀具的旋轉(zhuǎn)作用,還會(huì)將切削下的土壤向后拋送。另外,提輥式拔棉稈機(jī)械還要克服前進(jìn)阻力。因此,提輥式拔棉稈機(jī)功率消耗可表示為
（5-1）
式中 －旋切功耗；——拋土功耗；——旋切部件前進(jìn)滾阻功耗。
1） 旋切功耗
（5-2）
式中： —刃角；
—土壤與刀的滑動(dòng)摩擦系數(shù)；
F—刃面上的法向力（N）；
k—單位刀寬刃口切削阻力（N）；
b—刀寬（m）[10]
2） 拋土功耗
（5-3）
式中：Q—每秒拋出土量（kg/s）；
H—將土壤提升到拋土出口的高度（m）；
T—土壤與刀表面的摩擦力(m/s)；
Va-刀內(nèi)始端與外末端線速度均值(m/s)；
F-土壤與上弧形面的摩擦力(N)；
S-拋土位移(m)；
V-刀外末端線速度(m/s)；
M -每秒拋的土質(zhì)量(kg)。
3)旋切部件前進(jìn)滾阻功耗。
（5-4）
式中: K一旋切比阻
Kg—取Kg= 15；
—耕深修正系數(shù)；
—土壤含水率修正系數(shù)；
—植被修正系數(shù)；
—作業(yè)方式修正系數(shù)；
h—入土深度（m）；
V—作業(yè)速度（m/s）；
B—作業(yè)幅寬（m）[13]。
在上面各項(xiàng)阻力計(jì)算中,參數(shù)要根據(jù)實(shí)際工作地的土壤及機(jī)具條件確定。在提滾式拔棉稈機(jī)的工作過程中,提輥式拔棉稈的功耗大小主要由機(jī)具牽引速度、提輥直徑、耕深比和提輥轉(zhuǎn)速?zèng)Q定。通過計(jì)算分析,分別得出牽引速度與牽引阻力函數(shù)如圖5-1所示,提輥轉(zhuǎn)速與功率消耗函數(shù)如圖5-2所示,提輥直徑耕深之比與牽引阻力函數(shù)如圖5-3所示。
圖 5-1 牽引速度與牽引阻力關(guān)系
圖 5-2 提輥轉(zhuǎn)速與功率消耗關(guān)系
圖5-3 提輥直徑耕深之比與阻力關(guān)系
由牽引阻力與各參數(shù)函數(shù)圖像關(guān)系可知,牽引阻力與前進(jìn)速度和提輥轉(zhuǎn)速成正比關(guān)系,而與提輥直徑耕深之比成反比關(guān)系。在提輥式拔棉稈作業(yè)中,綜合考慮提輥?zhàn)鳂I(yè)效果與阻力消耗,并通過試驗(yàn)得出提滾直徑與耕深之比選擇1.2較為合適。在拖拉機(jī)牽引速度為4km/h的前提下,提輥轉(zhuǎn)速越高,拖拉機(jī)功率消耗越大;轉(zhuǎn)速越小,功率消耗越小,但是對(duì)土壤的切削力小,又不利于拔棉稈。綜合考慮上述因素,根據(jù)試驗(yàn),選擇轉(zhuǎn)速為320～ 360r/min較為合適。作業(yè)幅寬為3m、前進(jìn)速度為4km/h以及提輥轉(zhuǎn)速為630r/min時(shí),計(jì)算提輥在沙性土壤中的牽引功率約為27kW左右[14]。
5.3撥禾輪運(yùn)動(dòng)軌跡分析
撥禾輪是臥式收割機(jī)割曬機(jī)及全喂入式聯(lián)合收割機(jī)的重要工作部件，其主要功能是: 在撥禾輪的轉(zhuǎn)動(dòng)作用下，將作物引導(dǎo)撥向切割器; 在撥禾輪的扶持下，切割器完成作物的切割，已割作物向后推送[15]。撥禾輪除隨機(jī)器按一定前進(jìn)速度做勻速運(yùn)動(dòng)外，還要繞其軸心以一定的角速度ω做旋轉(zhuǎn)運(yùn)動(dòng)。其工作原理見圖 5-4 所示。
圖 5-4 撥禾輪工作原理圖
以撥禾輪軸心 對(duì)地面的投影點(diǎn)為坐標(biāo)原點(diǎn) O，以地面線沿前進(jìn)方向?yàn)?X 軸，以過原點(diǎn)向上垂線為 Y軸，建立坐標(biāo)系，且設(shè)撥板由水平位置開始以角速度ω 逆向旋轉(zhuǎn)，則壓板端點(diǎn) A 的坐標(biāo)方程為
（5-5）
（5-6）
式中: R—撥禾輪半徑；
ω—撥禾輪角速度；
—機(jī)器前進(jìn)速度；
t—撥板由水平轉(zhuǎn)過的時(shí)間；
H—撥禾輪安裝高度；
h—割茬高度。
當(dāng)撥禾輪速比( 撥禾輪旋轉(zhuǎn)線速度與機(jī)器前進(jìn)速度的比值) λ≤1 時(shí)，撥禾輪起不到應(yīng)有的功能; 當(dāng) λ ＞1 時(shí)，撥板的運(yùn)動(dòng)軌跡為余擺線，撥禾輪才具有前述的
三條功能。不同 λ 值時(shí)的撥板運(yùn)動(dòng)軌跡見圖 5-5 所示[16]。
圖5-5 不同λ值時(shí)的撥禾輪運(yùn)動(dòng)軌跡
5.4傳送帶的設(shè)計(jì)計(jì)算
其中確定傳送帶軸直徑為5cm，電機(jī)轉(zhuǎn)速為800r/min。傳送帶輪與電機(jī)帶輪直徑1：1，所以確定傳送帶軸轉(zhuǎn)速為800r/min。
傳送帶軸周長：C =2πr=3.14×5=15.7cm
線速度v=800c=800×15.7=12560cm/min
所以傳送帶運(yùn)行速度為=12560/6000=2.09m/s
總 結(jié)
棉花是主要的經(jīng)濟(jì)作物之一，棉花秸稈也是棉花的主要副產(chǎn)品，但是大部分棉稈都是采用粉碎還田方式處理，只有少部分進(jìn)行再利用。這是我課題研究的動(dòng)機(jī)對(duì)，搞好棉花秸稈的綜合利用,加快推進(jìn)棉花秸稈綜合利用,實(shí)現(xiàn)棉花秸稈的資源化和商品化,對(duì)國家促進(jìn)資源節(jié)約、環(huán)境保護(hù)和農(nóng)民增收具有的重大意義。所以說棉花秸稈收獲裝備對(duì)實(shí)現(xiàn)棉花秸稈的資源化和商品化至為關(guān)。希望這個(gè)設(shè)計(jì)能真正實(shí)際運(yùn)用到棉稈收獲中。
這次的設(shè)計(jì)從選題到實(shí)現(xiàn)，幾乎都是自己獨(dú)立完成的，這次畢業(yè)設(shè)計(jì)讓我更加熟悉了從理論到實(shí)踐的跨越，從當(dāng)初的各處查閱圖書到實(shí)地考察調(diào)研記錄，都有很多值得回味的地方。
通過本次設(shè)計(jì)，我學(xué)會(huì)了如何對(duì)進(jìn)行合理分析。同時(shí)，在本次設(shè)計(jì)過程中同時(shí)了解了如何編寫技術(shù)文件和正確使用設(shè)計(jì)手冊(cè)，也使我們對(duì)畫圖軟件的應(yīng)用能力有了很大提高，更培養(yǎng)了我們嚴(yán)肅認(rèn)真、一絲不茍和實(shí)事求是的學(xué)習(xí)和工作態(tài)度。
致 謝
本次設(shè)計(jì)能順利完成，首先要感謝李平老師的悉心指導(dǎo)，從選題到設(shè)計(jì)完成的整個(gè)過程中，遇到了很多問題，李平老師都能及時(shí)給予細(xì)心及準(zhǔn)確的指導(dǎo)，在設(shè)計(jì)思路出現(xiàn)混淆或錯(cuò)誤時(shí)，用淺顯易懂的知識(shí)深度剖析，使我的設(shè)計(jì)思路清晰明朗，以免在設(shè)計(jì)過程中迷失方向，出現(xiàn)大的偏差。在整個(gè)設(shè)計(jì)過程中，老師都能一如既往的表現(xiàn)出高度負(fù)責(zé)的工作態(tài)度和精益求精的工作作風(fēng)，這些都是我所應(yīng)該學(xué)習(xí)的。在此，對(duì)李平老師表示誠摯的感謝！
感謝母校為我提供了學(xué)習(xí)機(jī)會(huì)，使我的知識(shí)水平和認(rèn)知能力得以提高，同時(shí)為我們提供了良好的學(xué)習(xí)條件，在設(shè)計(jì)過程中難免會(huì)遇到課程中沒有學(xué)習(xí)到的知識(shí)點(diǎn)，這時(shí)，到塔里木大學(xué)圖書館便能找到想要的資料。
感謝老師四年來對(duì)我的精心栽培，感謝學(xué)校領(lǐng)導(dǎo)和老師們給予的幫助與關(guān)懷，感謝與我共同學(xué)習(xí)和生活了多年的同學(xué)們對(duì)我的關(guān)心與支持！
經(jīng)過對(duì)自己設(shè)計(jì)的深入思考和研究，對(duì)本設(shè)計(jì)所涉及的知識(shí)有了更深刻地理解。我的設(shè)計(jì)的主要部件有機(jī)架、皮帶傳送裝置、滾軸、工作臺(tái)，每一部分的設(shè)計(jì)都經(jīng)過了計(jì)算和驗(yàn)證，以及不斷地修改和改進(jìn)。并且采用了SolidWorks制圖技術(shù)和AutoCAD制圖技術(shù)等。畢業(yè)設(shè)計(jì)是對(duì)所學(xué)知識(shí)的一次大總結(jié)，在設(shè)計(jì)之前，收集有關(guān)設(shè)計(jì)課題研究方面的資料、文獻(xiàn)是最為重要的。在設(shè)計(jì)工作開始時(shí)，只有對(duì)課題研究的內(nèi)容充分地了解，才會(huì)有設(shè)計(jì)目的和方向；所以收集、查閱有關(guān)文獻(xiàn)資料是必要的。畢業(yè)設(shè)計(jì)的目的主要是培養(yǎng)我們運(yùn)用所學(xué)理論知識(shí)和專業(yè)知識(shí)來分析和解決機(jī)構(gòu)設(shè)計(jì)中所出現(xiàn)的一系列問題。本次的設(shè)計(jì)是幾年來學(xué)習(xí)過程中涵蓋面最廣的一次設(shè)計(jì)，它不僅體現(xiàn)了我們對(duì)機(jī)構(gòu)的設(shè)計(jì)，更重要的是對(duì)我們幾年來所學(xué)知識(shí)應(yīng)用到了實(shí)踐，使我明白了在今后設(shè)計(jì)過程中的一般步驟和方法。
總之，本次設(shè)計(jì)讓我受益匪淺，各方面的能力都有了提高。但由于本人設(shè)計(jì)能力有限，再加上實(shí)踐能力和經(jīng)驗(yàn)不足，設(shè)計(jì)中難免有不足之處。但通過設(shè)計(jì)使我各方面的能力都得到了很大提高，為今后工作和學(xué)習(xí)奠定了堅(jiān)實(shí)的基礎(chǔ)，我認(rèn)為這才是最重要的
參考文獻(xiàn)
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[4]胡凱，王吉奎，李斌，蔣蓓，丁雙雙，李天文.棉稈粉碎還田與殘膜回收聯(lián)合作業(yè)機(jī)研制與試驗(yàn)[J].石河子大學(xué)機(jī)械電氣工程學(xué)院,2013:3-9
[5]李怡.棉稈起拔機(jī)關(guān)鍵部件設(shè)計(jì)與實(shí)驗(yàn)研究[J].華中農(nóng)業(yè)大學(xué)碩士論文，2014:8-26
[6]郭振華,史建新,康秀生.提輥式拔棉稈阻力分析[J].農(nóng)業(yè)大學(xué)機(jī)械交通學(xué)院,2009:24-57
[7]趙東波.棉花拔稈清膜旋耕機(jī)研究設(shè)計(jì)[J].昌吉州農(nóng)牧機(jī)械化技術(shù)推廣站,2010:6-85
[8]王吉奎，付威,王衛(wèi)兵，李斌.SMS-1500型秸稈粉碎與殘膜回收機(jī)的設(shè)計(jì)[J].石河子大學(xué)機(jī)械電氣工程學(xué)院,2011:51-86
[9]趙海軍,史建新.殘膜回收工藝探討[J].中國農(nóng)機(jī)化,2004:68-71.
[10]劉文海,馬衛(wèi)星.淺議棉稈殘膜機(jī)械回收[J].農(nóng)機(jī)化,2005:2
[11]王鋒德,燕曉輝,董世平,孫玉峰,王俊友.我國棉花秸稈收獲裝備及收儲(chǔ)運(yùn)技術(shù)路線分析[J].農(nóng)機(jī)化研究,2009,12:217-220.
[12]崔相全,馬繼春,薦世春,王小瑜,曲萍.我國棉花棉稈收獲機(jī)械現(xiàn)狀及發(fā)展趨勢(shì)[J].農(nóng)業(yè)裝備與車輛工程,2011,11:4-6.
[13]張佳喜,葉菲.我國棉花秸稈收獲裝備現(xiàn)狀分析[J].農(nóng)機(jī)化研究,2011,08:241-244
[14]陳明江,平英華,曲浩麗,陳永生.棉稈機(jī)械化收獲技術(shù)與裝備現(xiàn)狀及發(fā)展對(duì)策[J].中國農(nóng)機(jī)化,2012,05:23-26
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An ASABE Meeting Presentation Paper Number: 084469
7760 Cotton Picker
Jason D. Wattonville
John Deere Des Moines Works, Ankeny, Iowa, USA
Written for presentation at the 2008 ASABE Annual International Meeting Sponsored by ASABE Rhode Island Convention Center Providence, Rhode Island June 29 - July 2，2008
Abstract. 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 Machinery
The 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: Author's 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@asabe.org or 269-429-0300 (2950 Niles Road, St. Joseph, Ml 49085-9659 USA).
7760 Cotton Picker
Introduction
Feedback 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 Approach
project Description
FigCire 2. Current Basket Picker Harvesting Process
Typically, 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 80’s.
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 the machine. 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 option
The 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 Requirements
Model
7760
Productivity increase over 9996
20%
Ability to non-stop harvest (up to 4 bale/acre yields at 4.2 mph)
Yes
Fluid capacity
12 hrs Continuous
Improved shift-ability
Yes
Locked wheel during powered brake turn
Yes
Field transport height
Equivalent to 9996
Shipping height
Equivalent to 9996
Flotation
Equal or greater than 9996
Tractive efficiency
Equal or greater than 9996
Tractive effort
Equal or greater than 9996
Standard front dual drive tires
Yes
Option single front drive tires
No
Improved maneuverability over 9996
Yes
Tier III emissions compliant
? Yes
Accumulator Round Module Builder j Wrap Mechanism
Figure 3. Machine Cut-Away
Theory of Operation
'i 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.
Accumulator
Accumulator 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 f「om 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.
Feeder
Cotton 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 Builder
The 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 System
The 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.
Handler
The 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 position
ltAuto" Mode Module Building
"Auto" 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 Features
Non-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 Station
The 7760 features a newly designed cab for a much improved operator's 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 console
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Electronic Unit Synchronization
Currently, 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 Transmission
The 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 Drive
ProDrive? 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 Module
The 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 Mainframe
The 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 System
In 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 Axle
The 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 axle
By 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 Comparison
Rear axle weight comparisons
9996= 18,000 lbs 7760 = 38,000 lbs 111% increase in rear axle weight Tread setting options
Same for both a 9996 and 7760 - 30,32,36,38 & 40 in Oscillation comparison 9996 = 8.3 deg 7760 = 9.0 deg
8.4% increase oscillation angle Wheel base comparison
9996= 141" (3.58m)
7760 = 170" (4.32m)
20.6% increase in wheel base Steer angle comparison 9996 = 41 deg 7760 = 55 deg
34.1 % increase in steer angle
Turning 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 radius
Ground compaction
Within 2-3 psi of 9996
Round Module Handling
Figure 9. Round Module Handler CM1100
Figure 8. Staging Round Modules
It 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, there’s 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.
11
Table 2: Machine Specifications
Figure 10. Round Modules in Standing Water
Figure 11. Waste from Conventional Modules
Module Transporting
The 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 Truck Figure 13. Flatbed Trailers
Ginning
We’ve 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