謝建華，唐 煒，張學(xué)軍，張鳳賢，楊豫新，段威林

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擺桿驅(qū)動(dòng)式殘膜回收機(jī)的設(shè)計(jì)與參數(shù)優(yōu)化

謝建華，唐 煒，張學(xué)軍，張鳳賢，楊豫新，段威林

（新疆農(nóng)業(yè)大學(xué)機(jī)電工程學(xué)院，烏魯木齊 830052）

針對(duì)現(xiàn)有的桿齒式殘膜回收機(jī)存在拾膜彈齒軸易卡頓、卸膜不可靠等問(wèn)題，改進(jìn)設(shè)計(jì)了擺桿驅(qū)動(dòng)式殘膜回收機(jī)。在原桿齒式殘膜回收機(jī)的基礎(chǔ)之上增加了起膜裝置，改變了拾膜齒軸與支撐盤的連接方式，利用四桿機(jī)構(gòu)將卸膜機(jī)構(gòu)的回轉(zhuǎn)運(yùn)動(dòng)轉(zhuǎn)變?yōu)閿[動(dòng)往復(fù)運(yùn)動(dòng)。為確定機(jī)具作業(yè)時(shí)的最優(yōu)參數(shù)組合，優(yōu)化整機(jī)結(jié)構(gòu)，以拾膜齒入土深度、土槽臺(tái)車前進(jìn)速度、拾膜齒線速度與土槽臺(tái)車前進(jìn)速度比（速比）為主要因素，拾膜率、卸膜率為評(píng)價(jià)指標(biāo)，對(duì)拾膜機(jī)構(gòu)和卸膜機(jī)構(gòu)進(jìn)行三因素三水平響應(yīng)面試驗(yàn)。通過(guò)Design-Expert數(shù)據(jù)分析軟件，建立各因素與拾膜率、卸膜率的二次回歸模型，分析了各因素對(duì)拾膜率、卸膜率的顯著性，結(jié)果表明各因素影響拾膜、卸膜率的大小順序?yàn)椋和敛叟_(tái)車前進(jìn)速度、拾膜齒線速度與土槽臺(tái)車前進(jìn)速度比、拾膜齒入土深度。并對(duì)試驗(yàn)參數(shù)進(jìn)行優(yōu)化，確定了最佳工作參數(shù)組合為拾膜齒入土深度為65 mm，土槽臺(tái)車前進(jìn)速度為1.2 m/s，速比為1.0。根據(jù)優(yōu)化結(jié)果進(jìn)行驗(yàn)證試驗(yàn)，結(jié)果表明拾膜率為85.6%，卸膜率為86.7%，預(yù)測(cè)模型與試驗(yàn)結(jié)果相差較小，優(yōu)化后的模型可靠。

機(jī)械化；優(yōu)化；設(shè)計(jì)；殘膜回收；擺桿驅(qū)動(dòng)；響應(yīng)面試驗(yàn)

0 引 言

地膜覆蓋栽培技術(shù)給農(nóng)業(yè)生產(chǎn)帶來(lái)極大發(fā)展的同時(shí)，殘留在田間的地膜也嚴(yán)重污染了土壤[1-5]。由于塑料地膜在自然條件下很難降解，殘留在土壤中不僅阻礙作物根系的生長(zhǎng)，還會(huì)阻止土壤中水分的滲透，使土壤含水率下降，作物吸水困難，并最終導(dǎo)致作物減產(chǎn)[6-9]。國(guó)外農(nóng)業(yè)種植使用的地膜通常較厚，由于其強(qiáng)度高、耐風(fēng)化的特點(diǎn)，一般采用結(jié)構(gòu)簡(jiǎn)單、制造成本低的收卷式殘膜回收裝置回收殘膜[10]。國(guó)內(nèi)大部分地區(qū)使用厚度不超過(guò)0.01 mm的薄地膜，薄地膜力學(xué)性能差，殘膜回收難度大。目前新疆等大面積覆膜種植區(qū)域主要采用機(jī)械化方式回收殘膜[11-13]。殘膜回收機(jī)根據(jù)農(nóng)時(shí)的不同可分為苗期殘膜回收機(jī)、播前殘膜回收機(jī)和秋后殘膜回收機(jī)[14-15]。王科杰等[16]設(shè)計(jì)了一種單組仿形功能的耙齒式殘膜回收機(jī)，拾膜率達(dá)到86.5%，該機(jī)具只能將殘膜收集堆卸在田間或地頭，由后續(xù)液壓打包機(jī)打包運(yùn)出田間。王吉奎等[17]針對(duì)秋后棉田殘膜回收，研制出結(jié)合棉桿粉碎的SMS-1500 型殘膜回收機(jī)，該機(jī)拾膜率大于90%，但存在卸膜機(jī)構(gòu)容易與殘膜纏繞的問(wèn)題。王旭峰等[18]設(shè)計(jì)了一種帶自卸膜裝置的拋膜鏈齒輸送殘膜回收機(jī)，但其結(jié)構(gòu)復(fù)雜，機(jī)具可靠性不高。嚴(yán)偉等[19]針對(duì)鏟篩式殘膜回收機(jī)進(jìn)行了優(yōu)化試驗(yàn)，其清土效果好，殘膜回收率高，但輸膜性能較差。

現(xiàn)有殘膜回收機(jī)主要分為桿齒式、鏈齒式、伸縮桿齒式及摟耙式等機(jī)型[20]，其中，摟耙式和桿齒式使用較普遍。摟耙式殘膜回收機(jī)作業(yè)效率高，結(jié)構(gòu)簡(jiǎn)單，使用可靠，但功能單一，需要人工或其他機(jī)具配合撿拾，且回收的殘膜含雜率較高。桿齒式殘膜回收機(jī)具主要采用彈齒扎膜的方式回收地表殘膜，機(jī)具結(jié)構(gòu)較簡(jiǎn)單，可靠性較好，但卸膜困難，作業(yè)部件易纏繞地膜，殘膜最終回收率不高[21-22]。本文根據(jù)新疆棉田地膜種植情況，綜合桿齒式殘膜回收機(jī)的結(jié)構(gòu)特點(diǎn)[23]，在對(duì)彈齒拾膜裝置、刮板卸膜裝置進(jìn)行技術(shù)改進(jìn)的基礎(chǔ)上，設(shè)計(jì)了一種擺桿驅(qū)動(dòng)式殘膜回收機(jī)。并通過(guò)三因素三水平響應(yīng)面試驗(yàn)和二次回歸模型的優(yōu)化獲得機(jī)具最優(yōu)工作參數(shù)，為后續(xù)物理樣機(jī)的加工和制作提供理論與試驗(yàn)依據(jù)。

1 機(jī)具的結(jié)構(gòu)及工作原理

圖1為擺桿驅(qū)動(dòng)式殘膜回收機(jī)的結(jié)構(gòu)示意圖，主要由行走輪、集膜箱、輸膜輥、卸膜軸總成、拾膜機(jī)構(gòu)、起膜裝置、邊膜鏟、卸膜驅(qū)動(dòng)裝置組成。其中，邊膜鏟、起膜裝置和拾膜機(jī)構(gòu)實(shí)現(xiàn)殘膜的撿拾；卸膜驅(qū)動(dòng)裝置、卸膜軸總成和輸膜輥實(shí)現(xiàn)殘膜的脫卸。

工作時(shí)機(jī)具由拖拉機(jī)牽引前進(jìn)，邊膜鏟將地膜兩邊的板結(jié)覆膜土耕松，起膜裝置將膜下土壤和地膜分離，并將地膜抬起一定高度。地輪前進(jìn)的同時(shí)將動(dòng)力傳遞給拾膜機(jī)構(gòu)，拾膜機(jī)構(gòu)在起膜裝置和邊膜鏟的配合下將地表殘膜挑起向卸膜位置輸送。卸膜桿齒在卸膜驅(qū)動(dòng)裝置的帶動(dòng)下，在一定范圍內(nèi)擺動(dòng)，將殘膜從拾膜桿齒上捋下，并在輸膜輥的帶動(dòng)下輸入集膜箱后部。

1.機(jī)架 2.地輪 3.集膜箱 4.輸膜輥 5.卸膜軸總成 6.起膜裝置 7.拾膜機(jī)構(gòu) 8.邊膜鏟 9.卸膜驅(qū)動(dòng)裝置

2 主要部件的設(shè)計(jì)與分析

2.1 拾膜機(jī)構(gòu)

原桿齒式殘膜回收機(jī)的拾膜齒軸直接穿在芯軸兩端的支撐盤孔內(nèi)（屬于滑動(dòng)連接），由于加工和制造精度的限制，拾膜機(jī)構(gòu)在工作過(guò)程中存在的沖擊、振動(dòng)及卡頓現(xiàn)象，影響拾膜效果。在優(yōu)化滑道軌跡的基礎(chǔ)上，采用單耳帶座軸承將拾膜齒軸與固定盤連接，將原來(lái)的滑動(dòng)連接變?yōu)闈L動(dòng)連接，使機(jī)構(gòu)運(yùn)動(dòng)平穩(wěn)性得到提高。

拾膜機(jī)構(gòu)如圖2所示，主要包括支撐盤、主軸、拾膜齒、拾膜齒軸、防護(hù)罩、曲柄、滑道、滾子等。拾膜齒固定在拾膜齒軸上，拾膜齒軸通過(guò)單耳帶座軸承與左、右支撐盤聯(lián)接，左、右支撐盤固定在主軸上。拾膜齒軸的一端固接曲柄，曲柄與滾子鉸接，滾子在滑道內(nèi)滾動(dòng)。拾膜齒在拾膜齒軸、曲柄、滾子和滑道的作用下，由前下方低頭入土向后方挑膜，在起膜裝置的輔助下將殘地膜挑起，再平移、后退、反轉(zhuǎn)，實(shí)現(xiàn)撿拾、升運(yùn)、卸膜和回程4個(gè)工作步驟。為保證撿拾殘膜的連續(xù)性，拾膜機(jī)構(gòu)均勻布置四組拾膜齒軸，根據(jù)新疆一膜四行機(jī)采棉種植模式，拾膜齒軸上勻布7個(gè)拾膜齒。

1.主軸 2.左支撐盤 3.單耳帶座軸承 4.拾膜齒 5.拾膜齒軸 6.右支撐盤 7.滾子 8.滑道 9.曲柄 10.防護(hù)罩

拾膜齒在拾膜齒軸上的排列間距的大小對(duì)拾膜效果有直接影響。排列間距小，可以提高機(jī)具的拾膜率，但易造成田間雜物壅堵，影響機(jī)具正常工作；排列間距過(guò)大，單個(gè)拾膜齒負(fù)責(zé)回收的區(qū)域增大，容易造成殘膜漏撿，或在撿拾運(yùn)送的過(guò)程中脫落。根據(jù)新疆一膜四行機(jī)采棉種植模式和前期的性能試驗(yàn)，拾膜齒軸上相鄰兩拾膜齒的中心距設(shè)置為165 mm。

機(jī)具在工作時(shí)，拾膜機(jī)構(gòu)轉(zhuǎn)速的大小影響機(jī)具的拾膜效果。轉(zhuǎn)速過(guò)快，拾膜桿齒向卸膜位置輸送殘膜時(shí)容易將殘膜拉斷；轉(zhuǎn)速過(guò)小，被挑起的殘膜會(huì)從拾膜桿齒上滑落。拾膜齒在拾膜過(guò)程中，拾膜主軸以的角速度轉(zhuǎn)動(dòng)時(shí)，被拾膜齒挑起殘膜的受力情況如圖3所示。

注：ω為拾膜主軸轉(zhuǎn)速，rad·s-1；G為殘膜自身重力，N；G1為殘膜自身重力沿桿齒方向上的分力，Ν；G2為殘膜自身重力垂直桿齒方向上的分力，Ν；Fg為殘膜所受的慣性力，Ν；α為拾膜齒與垂直方向的夾角，(°)；γ為慣性力與支持力間的夾角，(°)。

由圖3可知，拾膜齒在輸送殘膜時(shí)對(duì)殘膜的支持力為

殘膜在拾膜齒的運(yùn)送過(guò)程中不脫落的條件是殘膜與拾膜齒間的摩擦力大于拾膜時(shí)對(duì)殘膜的離心力，即

式中F為拾膜齒對(duì)殘膜的支持力，N；為被挑起殘膜的瞬時(shí)加速度，m/s2；為被挑起殘膜中心的瞬時(shí)半徑，m。

當(dāng)拾膜齒末端線速度=1.2 m/s、拾膜齒挑膜半徑=350 mm，可確定拾膜機(jī)構(gòu)轉(zhuǎn)速為=60/2π，約為33 r/min。

2.2 起膜裝置

起膜裝置如圖4所示，主要由安裝板、起膜齒軸、起膜齒組成。起膜齒固定在起膜齒軸上，安裝板將起膜裝置安裝在機(jī)架上。起膜齒在起膜齒軸上排列時(shí)應(yīng)當(dāng)盡可能的避免與根茬觸碰，為了避開棉花根茬，相鄰兩起膜齒的距離設(shè)置為110 mm。起膜齒的入土角不但影響起膜效果，而且與機(jī)具的工作阻力直接相關(guān)。根據(jù)起膜裝置的部件試驗(yàn)，確定起膜齒入土角1為22°。

1.安裝板 2.起膜齒軸 3.起膜齒

1.Assembling panel 2.Lifting film shaft 3.Lifting film tooth

注：1為起膜齒入土角，(°)。

Note:1is the penetration angle of film nail tooth, (°).

圖4 起膜裝置結(jié)構(gòu)示意圖

Fig.4 Structure diagram of lifting film device

2.3 擺桿驅(qū)動(dòng)式卸膜機(jī)構(gòu)

由于原桿齒式殘膜回收機(jī)的旋轉(zhuǎn)刮板式卸膜機(jī)構(gòu)在工作時(shí)，若地膜破損不嚴(yán)重（呈長(zhǎng)條狀），地膜易纏繞在卸膜輥軸上。將原旋轉(zhuǎn)刮板式卸膜機(jī)構(gòu)改進(jìn)為擺桿驅(qū)動(dòng)式卸膜機(jī)構(gòu)，利用四桿機(jī)構(gòu)將卸膜機(jī)構(gòu)的回轉(zhuǎn)運(yùn)動(dòng)轉(zhuǎn)變?yōu)閿[動(dòng)往復(fù)運(yùn)動(dòng)，減少了殘膜纏繞情況。擺桿驅(qū)動(dòng)式卸膜機(jī)構(gòu)如圖5所示，主要由卸膜驅(qū)動(dòng)裝置和卸膜軸總成組成，其中卸膜驅(qū)動(dòng)裝置包括擺桿、導(dǎo)桿和曲柄，卸膜軸總成由卸膜齒和卸膜軸組成。

1.機(jī)架 2.擺桿 3.卸膜軸總成 4.導(dǎo)桿 5.曲柄 6.曲柄轉(zhuǎn)動(dòng)軸

由于曲柄搖桿機(jī)構(gòu)能將圓周運(yùn)動(dòng)轉(zhuǎn)換為往復(fù)擺動(dòng)，且制造簡(jiǎn)單、可靠性高，因此，選擇曲柄搖桿機(jī)構(gòu)作為機(jī)具的卸膜驅(qū)動(dòng)裝置。卸膜桿齒擺角的大小對(duì)擺桿驅(qū)動(dòng)式殘膜回收機(jī)的卸膜率起決定作用，擺角過(guò)大，會(huì)使卸膜驅(qū)動(dòng)裝置的整體尺寸加大，在工作時(shí)降低機(jī)具的動(dòng)平衡性能，擺角過(guò)小會(huì)使卸膜桿齒不能將殘膜刮入集膜箱，導(dǎo)致殘膜掛在機(jī)具上或掉落田間，降低機(jī)具的卸膜率，通過(guò)卸膜機(jī)構(gòu)的性能試驗(yàn)設(shè)定擺角為110°。

如圖6所示，已知卸膜驅(qū)動(dòng)機(jī)構(gòu)的機(jī)架的長(zhǎng)度l為710 mm，擺桿的長(zhǎng)度l為190 mm，以點(diǎn)為圓心、l為半徑做圓弧12，使擺角為110o，設(shè)導(dǎo)桿、曲柄的長(zhǎng)度分別為l、l，則由曲柄存在條件

若導(dǎo)桿的長(zhǎng)度l為680 mm，通過(guò)式（3）可得l=160 mm。

注：l為曲柄的長(zhǎng)度，mm；l為導(dǎo)桿的長(zhǎng)度，mm；l為擺桿的長(zhǎng)度，mm；l為機(jī)架的長(zhǎng)度，mm；為擺桿的擺角，(°)；1、2為卸膜齒運(yùn)動(dòng)端點(diǎn)。

Note: lis the length of crank, mm;lis the length of guide rod, mm;lis the length of swing rod, mm;lis the length of frame, mm;is the swing angle of swing rod, (°);1and2are the moving end point of unloading film tooth.

圖6 卸膜驅(qū)動(dòng)機(jī)構(gòu)結(jié)構(gòu)參數(shù)分析

Fig.6 Analysis of structural parameters of film driving mechanism

3 試驗(yàn)條件及方法

為驗(yàn)證機(jī)構(gòu)性能及確定后續(xù)樣機(jī)結(jié)構(gòu)參數(shù)和主要工作參數(shù)，對(duì)拾膜機(jī)構(gòu)和卸膜機(jī)構(gòu)進(jìn)行試驗(yàn)。由于田間試驗(yàn)研究周期較長(zhǎng)，且不易觀察、測(cè)量，臺(tái)架試驗(yàn)可以模擬田間工作環(huán)境[24-25]完成部件性能測(cè)試。本文通過(guò)臺(tái)架土槽試驗(yàn)對(duì)改進(jìn)的拾膜機(jī)構(gòu)、擺桿驅(qū)動(dòng)式卸膜機(jī)構(gòu)的工作性能進(jìn)行測(cè)試，分析土槽臺(tái)車前進(jìn)速度、拾膜桿齒線速度與土槽臺(tái)車前進(jìn)速度比、拾膜齒入土深度3個(gè)因素對(duì)機(jī)具拾膜、卸膜效果的影響，通過(guò)臺(tái)架試驗(yàn)找出最優(yōu)結(jié)構(gòu)與工作參數(shù)組合，指導(dǎo)后續(xù)樣機(jī)的制作。

3.1 臺(tái)架試驗(yàn)條件

試驗(yàn)在牽引式土槽試驗(yàn)系統(tǒng)中進(jìn)行，如圖7所示，試驗(yàn)系統(tǒng)主要包括牽引式土槽臺(tái)車、拾膜機(jī)構(gòu)、擺桿驅(qū)動(dòng)式卸膜機(jī)構(gòu)、變頻器、電動(dòng)機(jī)和控制箱組成。試驗(yàn)時(shí)，拾膜、卸膜機(jī)構(gòu)與地面的相對(duì)距離固定，采取改變土槽內(nèi)的土壤厚度的方式來(lái)調(diào)整拾膜齒的入土深度。變頻器與電動(dòng)機(jī)連接，通過(guò)調(diào)節(jié)變頻器頻率的大小來(lái)控制電動(dòng)機(jī)的轉(zhuǎn)速，電動(dòng)機(jī)通過(guò)鏈傳動(dòng)帶動(dòng)拾膜、卸膜機(jī)構(gòu)工作，土槽臺(tái)車中土壤表層覆膜，并在地膜兩邊插入棉桿來(lái)模擬實(shí)際工作環(huán)境。

1.變頻器 2.電動(dòng)機(jī) 3.拾膜、卸膜機(jī)構(gòu) 4.牽引式土槽臺(tái)車 5.控制箱

試驗(yàn)時(shí)選用厚度為0.01 mm、覆膜天數(shù)約為180 d的舊地膜，按照(660+100) mm的機(jī)采棉種植模式鋪膜，兩邊覆土厚度為35～45 mm，土壤含水率為10%～20%。由于該機(jī)具作業(yè)對(duì)象為棉桿已經(jīng)被粉碎的棉田，因此，在殘膜上插入露出土壤表面高度為50～70 mm的棉花根茬。試驗(yàn)過(guò)程中動(dòng)力由路陽(yáng)紅404型拖拉機(jī)提供，選用天馬FA1004型電子天秤測(cè)量殘膜質(zhì)量。

3.2 試驗(yàn)指標(biāo)

根據(jù)NYT1227-2006殘膜回收機(jī)作業(yè)質(zhì)量標(biāo)準(zhǔn)選擇拾膜率和卸膜率作為試驗(yàn)指標(biāo)。將試驗(yàn)收集的殘膜清洗干凈并晾干，用電子天平稱質(zhì)量，計(jì)算機(jī)具的拾膜率、卸膜率，表達(dá)式為

式中1為拾膜率，%；2為卸膜率，%；M為被刮入膜箱中殘膜的質(zhì)量，g；M為未被挑起的殘膜的質(zhì)量，g；M為被挑起但未被刮入膜箱的殘膜的質(zhì)量，g。

3.3 試驗(yàn)設(shè)計(jì)

選取拾膜齒入土深度1、土槽臺(tái)車前進(jìn)速度2、拾膜齒線速度與土槽臺(tái)車前進(jìn)速度比33個(gè)因素，并根據(jù)機(jī)具的結(jié)構(gòu)以及設(shè)計(jì)參數(shù)確定拾膜齒入土深度分別取30、60、90 mm，土槽臺(tái)車前進(jìn)速度分別取慢Ⅲ檔（0.6 m/s）、慢Ⅳ檔（0.9 m/s）、快Ⅰ檔（1.2 m/s），拾膜齒線速度與土槽臺(tái)車前進(jìn)速度比分別取0.8、1.0和1.2。

本試驗(yàn)采用三因素三水平響應(yīng)面分析試驗(yàn)，表1為試驗(yàn)因素水平編碼表，表2為試驗(yàn)設(shè)計(jì)與試驗(yàn)結(jié)果，利用Design-Expert軟件設(shè)計(jì)試驗(yàn)，共進(jìn)行17組試驗(yàn)，對(duì)每組試驗(yàn)重復(fù)3次，并求得拾膜率、卸膜率的平均值為試驗(yàn)結(jié)果。

表1 試驗(yàn)因素水平編碼Table 1 Horizontal coding of test factors

注：速比為拾膜齒線速度與土槽臺(tái)車前進(jìn)速度比。

Note: Speed ratio is the ratio of linear speed of the picking-up tooth to forward speed of soil bin trolley.

4 試驗(yàn)結(jié)果及分析

4.1 試驗(yàn)回歸分析

表2 試驗(yàn)方案及結(jié)果

表3 回歸模型方差分析

注：<0.05(顯著*)；<0.01(極其顯著**)

Note:<0.05(significant,*);<0.01(highly significant, **)

4.2 試驗(yàn)因素對(duì)拾膜率、卸膜率的影響分析

利用Design-Expert中數(shù)據(jù)分析功能對(duì)表2中的試驗(yàn)結(jié)果進(jìn)行多元回歸擬合[29-31]，得到以拾膜齒入土深度、土槽臺(tái)車前進(jìn)速度及速比對(duì)拾膜率1、卸膜率2影響的回歸方程為

為了直觀反映不同交互因素對(duì)指標(biāo)影響的強(qiáng)弱[32-33]，根據(jù)二次回歸模型（6）和（7）作出各交互因素對(duì)拾膜率、卸膜率影響的響應(yīng)面圖，如圖8所示。

注：響應(yīng)面試驗(yàn)因素和水平見表1，響應(yīng)值見表2。

由圖8a可以看出，當(dāng)土槽臺(tái)車前進(jìn)速度在零水平，拾膜齒入土深度固定在低水平（30 mm）時(shí)，拾膜齒線速度與土槽臺(tái)車前進(jìn)速度比從0.8增加至1.0，拾膜率先增加，但增加到一定程度時(shí)，速比對(duì)拾膜率的影響趨于穩(wěn)定，主要是因?yàn)楫?dāng)拾膜齒入土挑膜并將殘膜向卸膜機(jī)構(gòu)輸送時(shí)，速比較低，拾膜機(jī)構(gòu)轉(zhuǎn)速低，挑起的殘膜由于自身重力的原因，從拾膜齒上滑落，速比增大，拾膜機(jī)構(gòu)轉(zhuǎn)速增大，減小了殘膜從拾膜齒上滑落的可能。

由圖8b可以看出，拾膜齒入土深度在零水平，速比保持在低水平（0.8）時(shí)，土槽臺(tái)車前進(jìn)速度從0.6 m/s增加至1.2 m/s，拾膜率呈現(xiàn)增大的趨勢(shì)，從總體來(lái)看，當(dāng)土槽臺(tái)車前進(jìn)速度和速比同時(shí)增加時(shí)，拾膜率呈現(xiàn)先增大后減小的趨勢(shì)，主要因?yàn)橥敛叟_(tái)車前進(jìn)速度和速比都增大時(shí)，拾膜機(jī)構(gòu)轉(zhuǎn)速也增大，但轉(zhuǎn)速過(guò)快時(shí)，拾膜齒向卸膜位置輸送殘膜時(shí)會(huì)將殘膜拉斷，影響收膜時(shí)的連續(xù)性。

從圖8c中可以看出，當(dāng)速比持續(xù)增加時(shí)，機(jī)具的卸膜率先增大后減小，這是由于當(dāng)速比過(guò)小時(shí)，殘膜會(huì)從卸膜齒上滑落，當(dāng)速比過(guò)大時(shí)，卸膜機(jī)構(gòu)往復(fù)周期過(guò)小，同時(shí)，由于殘膜的連續(xù)性遭到破壞，再加之破壞后的地膜更容易受到空氣阻力的影響，導(dǎo)致卸膜桿齒將后拋未落下的殘膜回帶，影響機(jī)具的卸膜率。從圖8d中可以看出，當(dāng)速比在零水平時(shí)，拾膜齒入土深度固定在一定水平時(shí)，卸膜率總體上隨土槽前進(jìn)速度的增大而增大，但增大到一定程度后，卸膜率也會(huì)有下降的趨勢(shì)，這是由于加快土槽臺(tái)車前進(jìn)速度時(shí)，要保證速比不變，就得加大拾膜、卸膜機(jī)構(gòu)的轉(zhuǎn)速，與上同理，也會(huì)使卸膜率降低。

4.3 參數(shù)優(yōu)化與驗(yàn)證試驗(yàn)

借助拾膜率、卸膜率的回歸方程模型式（6）和（7），以增大拾膜率和卸膜率為優(yōu)化目標(biāo)，應(yīng)用Design-Expert軟件中的優(yōu)化模塊，對(duì)拾膜、卸膜率的回歸方程模型進(jìn)行優(yōu)化求解，得到最優(yōu)工作參數(shù)為：拾膜齒入土深度為65 mm，土槽臺(tái)車前進(jìn)速度為1.2 m/s，速比為1.0，此時(shí)拾膜率為87.8%，卸膜率為87.9%。

為了驗(yàn)證優(yōu)化后模型的可行性，按照優(yōu)化后得到的參數(shù)進(jìn)行驗(yàn)證試驗(yàn)，設(shè)定拾膜齒入土深度為65 mm，土槽臺(tái)車前進(jìn)速度為1.2 m/s，速比為1.0，試驗(yàn)共進(jìn)行3次并對(duì)得到的數(shù)值求平均值，試驗(yàn)結(jié)果為拾膜率為85.6%，與預(yù)測(cè)值相差2.2%，與原桿齒式殘膜回收機(jī)相比提升4.71%；卸膜率為86.7%，與預(yù)測(cè)值相差1.2%，與原桿齒式殘膜回收機(jī)相比提升3.42%。試驗(yàn)值與理論優(yōu)化值的相對(duì)誤差均小于3%，優(yōu)化模型可靠，優(yōu)化后機(jī)構(gòu)的性能得到改善。

5 結(jié) 論

1）針對(duì)現(xiàn)有的桿齒式殘膜回收機(jī)存在拾膜彈齒軸易卡頓、卸膜不可靠等問(wèn)題，設(shè)計(jì)了擺桿驅(qū)動(dòng)式殘膜回收機(jī)，確定了拾膜機(jī)構(gòu)、起膜機(jī)構(gòu)、擺桿驅(qū)動(dòng)式卸膜機(jī)構(gòu)的設(shè)計(jì)參數(shù)。

2）以拾膜齒入土深度、土槽臺(tái)車前進(jìn)速度、拾膜齒線速度與土槽臺(tái)車前進(jìn)速度比為影響因素進(jìn)行試驗(yàn)，并通過(guò)Design-Expert軟件對(duì)試驗(yàn)結(jié)果進(jìn)行響應(yīng)面分析，結(jié)果表明，各因素影響拾膜、卸膜率的大小順序?yàn)椋和敛叟_(tái)車前進(jìn)速度、拾膜齒線速度與土槽臺(tái)車前進(jìn)速度比、拾膜齒入土深度。

3）利用Design-Expert軟件的數(shù)據(jù)優(yōu)化功能，以提高拾膜率、卸膜率為優(yōu)化目標(biāo)，確定最佳工作參數(shù)為：拾膜齒入土深度為65 mm，土槽臺(tái)車前進(jìn)速度為1.2 m/s，拾膜齒線速度與土槽臺(tái)車前進(jìn)速度比為1.0。對(duì)優(yōu)化后的各因素進(jìn)行驗(yàn)證試驗(yàn)，試驗(yàn)結(jié)果表明，拾膜率為85.6%，卸膜率為86.7%，優(yōu)化后的參數(shù)可作為機(jī)具作業(yè)的最佳依據(jù)。

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Design and parameter optimization of swing rod driven residual plastic film collector

Xie Jianhua, Tang Wei, Zhang Xuejun, Zhang Fengxian, Yang Yuxin, Duan Weilin

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Although plastic sheet-covered cultivation technology has brought great development to agricultural production, the plastic film residual in the field has also seriously polluted the soil. Because plastic film is difficult to degrade under natural conditions, its residue in the soil will not only hinder the growth of crop roots, and make it difficult for crops to absorb water, but also prevent the infiltration of water in the soil, making the soil moisture content decline, and ultimately leading to crop yield reduction. The traditional pole-tooth residual plastic film collector mainly uses elastic tooth to recover the surface plastic film residue. The structure of the machine is simple, but it is difficult to unload the plastic film, and the working parts are easy to be wrapped by the film, which ultimately leads to the low recovery rate of the plastic film residue. According to the typical mulching planting situation in Xinjiang cotton field and the structural characteristics of the pole-tooth residual plastic film collector, the swing rod driven residual plastic film collector was improved and designed. In particular, the technology improvement of the spring-tooth picking device and the scraper discharging device was carried out, which solved the problems of easy jamming of the elastic tooth shaft and unreliable film unloading. Compared with the traditional pole-tooth residual plastic film collector, the swing rod driven residual plastic film collector mainly improved in the following aspects: the lifting film device was increased, and the effect of picking-up film was improved; the connection mode between the picking-up tooth shaft and the supporting plate was changed, and the operation of the picking-up residual plastic film mechanism was improved; four-bar linkage was used to change the gyratory motion of unloading film mechanism into swing reciprocating motion, so as to reduce residual film winding. In order to verify the performance of the mechanism, determine the optimal combination of parameters, and optimize the structure of the whole machine, the picking-up film mechanism and the unloading film mechanism were tested. Taking the penetration depth of the picking-up teeth, the forward speed of the trolley, the linear speed of the picking-up teeth and the forward speed ratio (the ratio of linear speed of the picking-up tooth to forward speed of soil bin trolley) of the trolley as the main factors, and the picking-up rate and the unloading rate as the testing indexes, the three-factor and three-level response tests of the picking-up mechanism and the unloading mechanism were carried out. The quadratic regression model between each factor and the picking-up film rate and unloading film rate were established by the software of Design-Expert. The significant influence of each factor on the picking-up film rate and unloading film rate were analyzed, and the test parameters were optimized. The results showed that the order of influencing factors on the picking-up film rate and the unloading film rate was as follows: the forward speed of soil bin trolley, the speed ratio, and the depth of picking-up teeth into soil. The optimum working parameters were determined as follows: the penetration depth of the picking teeth of 65 mm, 1.2 m/s of the forward speed of the soil bin trolley, and the speed ratio of 1.0. According to the optimization results, the validation test was carried out. The result showed that the picking-up film rate was 85.6%, the unloading film rate was 86.7%, which were less different from the prediction model, and the optimized model was reliable.

mechanization; optimization; design; plastic film residue-collecting; swing rod driven; response surface experiments

謝建華，唐 煒，張學(xué)軍，張鳳賢，楊豫新，段威林. 擺桿驅(qū)動(dòng)式殘膜回收機(jī)的設(shè)計(jì)與參數(shù)優(yōu)化[J]. 農(nóng)業(yè)工程學(xué)報(bào)，2019，35(4)：56－63. doi：10.11975/j.issn.1002-6819.2019.04.007 http://www.tcsae.org

Xie Jianhua, Tang Wei, Zhang Xuejun, Zhang Fengxian, Yang Yuxin, Duan Weilin. Design and parameter optimization of swing rod driven residual plastic film collector[J]. Transactions of the Chinese Society of Agricultural Engineering (Transactions of the CSAE), 2019, 35(4): 56－63. (in Chinese with English abstract) doi：10.11975/j.issn.1002-6819.2019.04.007 http://www.tcsae.org

2018-09-10

2019-01-30

國(guó)家自然科學(xué)基金資助項(xiàng)目（51465057,51665057）；“十三五”國(guó)家重點(diǎn)研發(fā)計(jì)劃（2017YFD0701102-2）；中國(guó)農(nóng)大-新疆農(nóng)大聯(lián)合基金（2017TC009）

謝建華，副教授，博士，主要從事農(nóng)業(yè)機(jī)械設(shè)計(jì)與研究。 Email：xjh199032@163.com

10.11975/j.issn.1002-6819.2019.04.007

S223.5

A

1002-6819(2019)-04-0056-08