氣吸式紅棗收獲機(jī)的設(shè)計(jì)

氣吸式紅棗收獲機(jī)的設(shè)計(jì),氣吸式,紅棗,收獲,收成,設(shè)計(jì) 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