盘吸式水稻排种器吸种动力学过程模拟及参数优化

    Dynamic simulation of seed pick-up process and parameteroptimization on vacuum plate seeder for rice

    • 摘要: 准确控制盘吸式排种器的吸种位置是提高水稻育秧播种精度的关键因素,吸盘的吸种位置能够根据种盘内籽粒数量的变化进行自适应调节则是稳定排种器连续作业性能的重要保证。该文通过多球拟合建立了2种椭球体水稻籽粒模型,采用标准k-ε湍流模型和Euler气固两相流模型进行计算流体动力学和离散元(CFD-DEM)耦合,完成了排种器的吸种动力学过程仿真。根据籽粒的空间分布特点,采用均匀分布模型和矩估计法计算了籽粒的空间分布范围和离散系数,获取了垂直往复振动激励下的籽粒离散运动状态和稳定特性,确定了理想的种层厚度范围。以能够有效吸附籽粒为条件,仿真获取了不同种层厚度下的临界吸种位置,分析了吸种距离的变化规律、籽粒形状对吸种性能的影响以及造成漏吸和重吸的原因。受到籽粒相互碰撞挤压等因素影响,CFD-DEM仿真获取的吸种距离小于静止状态下的籽粒吸附临界距离,考虑到实际振动种盘内种群运动的随机性更强,提出在仿真获取的临界吸种位置基础上,适当降低调节距离以提高吸盘的整体吸种性能。结合振动种盘内种层厚度的实时监测技术,以PLC为控制器设计了排种器吸种位置的自动控制装置,并在排种器性能试验台上以压差、吸种位置调节距离、种盘振动频率、种层厚度为因素进行正交试验,通过对吸种合格率的数学回归建模和优化得到:当吸孔直径为2.5 mm、种盘振幅为4.0 mm时,理想的压差为4.4 kPa、种盘振动频率为10.6 Hz、吸种位置调节距离为2.7 mm。根据优化结果进行吸种性能试验,当种层厚度在15~25 mm范围变化时,排种器的吸种合格率达到94.5%。研究结果可以为提高盘吸式排种器的自动化水平和连续作业性能提供借鉴。

       

      Abstract: Abstract: The key factor to improve seeds pick-up accuracy of vacuum plate seeder is to control the suction position accurately. During the working progress, the number of seeds in vibrating tray is always changing. So, it is an important guarantee for improving the continuous working performance of seeder that the suction position of vacuum plate can be adjusted automatically according to the variation of seeds in vibrating tray. In the paper, 2 different ellipsoid paddy seeds models were established using multi-sphere fitting method, and the contact forces were calculated using Hertz-Mindlin model. Then, the kinetics simulations of seeds pick-up process were completed using CFD-DEM (computational fluid dynamics- discrete element method) coupling method which includes the standard k-ε turbulence model and Euler gas-solid two-phase model. According to the spatial distribution variation law of seeds in vibrating tray at different time, their distribution region and discrete coefficients were calculated using the uniform distribution model and the moment estimate algorithm. Discrete motion states and stability characteristics of seeds under excitation of vertical reciprocating vibration were obtained, and the reasonable range of seeds layer thickness was determined. Seeds pick-up processes were finished when the seeds were thrown up to the high point by vibrating tray, and the absorbed seeds were generally in the upper layer. Under the conditions that seeds could be picked up accurately, the critical suction position in different seeds layer thickness was determined, and then the variation of pick-up distance, the influence of seeds shape on the pick-up performance, and the reasons leading to seeds single pick-up, missing pick-up and repeated pick-up were analyzed. It was obtained that the repeated pick-up ratio will increase with the increasing of seeds ellipticity which leads to the strong leakage flow field. Under the influence of collision and extrusion between seeds, the pick-up distance received by simulations is less than the value at static condition. Considering the influence of uncertain motion state of seeds in actual vibrating tray is much stronger, a modification method of suction position was proposed to improve the overall seeds pick-up performance of vacuum plate. That is to properly reduce the regulated distance based on the critical suction position received by simulation. Combined with the real-time monitoring method of seeds mass, an adaptive control device of suction position of vacuum plate was designed using PLC (programmable logic controller) as the controller. Using the established suction position control model, and taking differential pressure, regulated distance of suction position, vibration frequency of tray and seeds layer thickness as factors, each nozzle picking-up 1-2 seeds as evaluating indicator, the orthogonal tests were carried out on precision seeder test-rig with the diameter of suction nozzle of 2.5 mm and vibration amplitude of tray of 4 mm. The mathematical regression equation of seeds pick-up qualified index was established based on orthogonal tests results, and it was shown that the differential pressure and regulated distance of suction position were the 2 major factors that affected operating performance. By optimizing the established mathematical regression equation, the ideal working parameters were received including differential pressure of 4.4 kPa, vibration frequency of 10.6 Hz, and regulated distance of suction position of 2.7 mm. Under the above optimization parameters, further seeds pick-up tests were carried out with the seeds layer thickness varying in the range of 15-25 mm, and the results indicated that the seeds pick- up qualified index could reach about 94.5%. The proposed control method of suction position according to the variation of seeds layer thickness in vibrating tray can provide references for improving automation level and operating performance of vacuum plate precision seeder.

       

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