基于颗粒放尺效应的逆旋开沟机刀辊功耗分析与试验

    Analysis and experiment of the power of blade roller in reverse-rotary ditching machine based on the granular scale effect

    • 摘要: 为探究粗粒化建模对逆旋开沟机刀辊功耗的影响,提高离散元法的计算效率,该研究以1K-50型开沟机开沟部件为对象,利用EDEM软件构建适于南方葡萄园土质环境的刀辊-土壤离散元模型,将仿真模型中的土壤颗粒分别放大2~5倍进行开沟仿真试验,对刀辊功耗、工作阻力及土壤运动状态进行分析。结果表明:在土壤颗粒直径为5 mm、刀辊转速132 r/min、前进速度0.06 m/s、开沟深度0.3 m工况下,刀辊稳定作业阶段的功耗、水平阻力及垂直阻力平均值分别为3.73 kW、923.85 N和148.30 N,仿真功耗相对实际功耗的误差为9.9%。开沟仿真过程中刀辊的功耗、工作阻力平均值及土壤运动状态随放尺比例的变化而变化,其中刀辊功耗与水平阻力平均值随放尺比例增大而减小,垂直阻力平均值随放尺比例先减小后增大再减小,且增大放尺比例使得土垡从刀片正切面的抛出时刻提前,抛出速度减小,土垡逐渐松散,壅土高度增加,但不改变正切面上各深度土层的土壤分布顺序。放尺比例为2~5时,仿真计算时间相较原尺状态减少99%,但仿真功耗相对实际功耗的误差超过32%,当放尺比例为1.2时,能够将功耗相对误差控制在11.1%,仿真时间为22.9 h,仿真数据量313.72 GB。研究结果可为农机领域离散元放尺计算及构建刀辊-土壤粗粒化模型提供一定参考。

       

      Abstract: Low accessibility of large ditching equipment cannot fully meet the narrow space in grape vineyards in southern China. Manual ditching is also low effectiveness and efficiency. Fortunately, a 1K-50 orchard ditching machine has been developed in this case. Nevertheless, some challenges still remained regarding the stability of trench depth, high power consumption, and severe vibration of the machine during ditching. One of the key components in the ditching machine, the blade roller can encounter significant resistance, as the blades make direct contact with the soil during operation. This resistance has posed a strong impact on the ditching power and vibration of the machine. It is very necessary to analyze the ditching power, working resistance, and soil movement during deep cultivation with a reverse-rotary ditching machine. The discrete element method (DEM) can be expected to explore the ditching power and vibration. Compared with the theoretical calculations and agricultural machinery experiments, the interaction between the blade roller and the soil can be determined to optimize the blade roller parameters and the soil flow state from a microscopic perspective. At the same time, efficiency can also be improved to reduce research costs. However, the number of high-magnitude particles can be limited to establish the soil particle model in a 1:1 physical scale, when discrete element software runs the large-scale agricultural machinery simulations. Coarsening can be used to simplify a complex particle model into a larger-scale particle combination without considering the relatively minor physical phenomena. System details can be removed to significantly reduce the computational load. Particle size, shape, and contact properties between particles are required for the key factors to consider in the coarsening process of the model. This study aims to clarify the influence of the scale ratio on the ditching power, working resistance, and soil movement state of the machine, in order to simplify the issue while considering the key factors. Taking the ditching component of the 1K-50 ditching machine as the research object, EDEM software was used to construct a blade roller-soil model suitable for the soil environment of grape vineyards in southern China. The simulated ditching test was conducted under the working conditions of a cutter roll speed of 132 r/min, forward speed of 0.06 m/s, and ditching depth of 0.3 m. The results show that the average ditching power, horizontal resistance, and vertical resistance were 3.73 kW, 923.85 N, and 148.30 N, respectively, in the original particle state during the stable operating stage of the blade roller. The error of simulated and actual ditching power was 9.9%. The enlarging diameter of soil particles caused the variation in the ditching power of the blade roller, working resistance, and soil movement state. Specifically, the average ditching power and horizontal resistance decreased with the increase in the scale ratio, while the average vertical resistance decreased first, then increased, and finally decreased again. The throwing speed decreased, and the shape of the thrown soil was loose at the advanced moment when the soil was thrown out from the forward section of the blade. But there was no change in the order of the soil distribution in the soil layers at different depths. The simulation time was reduced by more than 99% when the scale ratio was between 2 and 5. Nevertheless, the error exceeded 32% in the ditching power of the blade roller simulation, compared with the actual. Once the scale ratio was 1.2, the relative error of the model in the ditching power was kept at 11.1%, with a simulation time of 22.9 h and a simulation data volume of 313.72 GB. The findings can provide a strong reference for the discrete element coarsening in the field of agricultural machinery. A theoretical basis was also offered to construct a coarsened model of the blade roller-soil system.

       

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