電控玉米排種系統(tǒng)設(shè)計(jì)與試驗(yàn)

張春嶺 吳 榮 陳黎卿

(1.安徽農(nóng)業(yè)大學(xué)工學(xué)院， 合肥 230036； 2.華中農(nóng)業(yè)大學(xué)工學(xué)院， 武漢 430070)

電控玉米排種系統(tǒng)設(shè)計(jì)與試驗(yàn)

張春嶺1,2吳 榮1陳黎卿1

(1.安徽農(nóng)業(yè)大學(xué)工學(xué)院， 合肥 230036； 2.華中農(nóng)業(yè)大學(xué)工學(xué)院， 武漢 430070)

傳統(tǒng)精量玉米播種機(jī)作業(yè)時(shí)，排種器的動(dòng)力由地輪提供，針對(duì)由于田間作業(yè)工況復(fù)雜導(dǎo)致地輪打滑而造成漏播率增加等問題，設(shè)計(jì)了電控玉米排種系統(tǒng)。該系統(tǒng)在田間播種作業(yè)時(shí)，由雷達(dá)測(cè)速儀采集播種作業(yè)速度，結(jié)合所需粒距得到排種器理論轉(zhuǎn)速；通過編碼器采集排種器實(shí)時(shí)轉(zhuǎn)速，利用控制器控制策略，進(jìn)行轉(zhuǎn)速的最優(yōu)控制，從而得到目標(biāo)排種轉(zhuǎn)速，提高排種精度。田間試驗(yàn)結(jié)果表明：應(yīng)用該電控排種系統(tǒng)進(jìn)行田間玉米播種作業(yè)時(shí)，排種合格指數(shù)平均值為92.40%，與傳統(tǒng)排種相比提高3.63個(gè)百分點(diǎn)；漏播指數(shù)平均值為4.82%，與傳統(tǒng)排種相比降低2.04個(gè)百分點(diǎn)；不同播種作業(yè)工況下粒距變異系數(shù)均小于4.20%，播種效果好。

精量玉米播種機(jī)； 電控； 排種系統(tǒng)

引言

目前，玉米精量播種作業(yè)中多采用機(jī)械式排種器[1]，但其動(dòng)力常由地輪提供，由于田間作業(yè)工況復(fù)雜，地表不平整等易造成地輪打滑，從而增加漏播率[2-5]。國(guó)內(nèi)外對(duì)機(jī)械式玉米排種器的研究主要集中于結(jié)構(gòu)設(shè)計(jì)和性能參數(shù)優(yōu)化[6-9]，并未從根本上解決由地輪打滑帶來(lái)的漏播率增加問題。氣力式排種器雖然對(duì)種子損傷小、充填效果好，但其適宜于大豆等圓形類種子的播種，在播種玉米時(shí)漏播率和動(dòng)力消耗都較大，特別是在地頭時(shí)由于風(fēng)機(jī)轉(zhuǎn)速不夠、氣壓不足，漏播現(xiàn)象更嚴(yán)重；而且其結(jié)構(gòu)復(fù)雜，價(jià)格昂貴，使其推廣使用受到限制[10-12]。

近些年，農(nóng)業(yè)機(jī)械控制系統(tǒng)的控制策略主要依據(jù)PID控制算法[13-15]，但大部分都集中于精準(zhǔn)施肥控制器上，且模糊算法使用居多，而在精準(zhǔn)排種器上的研究較少[16-23]。

針對(duì)以上問題，本文設(shè)計(jì)一款電控排種系統(tǒng)。該系統(tǒng)應(yīng)用雷達(dá)測(cè)速儀采集播種作業(yè)速度，采用無(wú)刷直流電動(dòng)機(jī)作為排種器的動(dòng)力源，基于遺傳算法整定PID參數(shù)，使得排種器旋轉(zhuǎn)速度與播種作業(yè)速度保持同步，從而提高排種精度，并實(shí)現(xiàn)精準(zhǔn)排種的最優(yōu)控制。

1 電控排種系統(tǒng)作業(yè)原理

電控排種系統(tǒng)作業(yè)原理框圖如圖1所示。排種作業(yè)時(shí)，由雷達(dá)測(cè)速儀檢測(cè)播種實(shí)時(shí)作業(yè)速度，將其與輸入株距聯(lián)合計(jì)算得到排種器理論轉(zhuǎn)速；同時(shí)，由旋轉(zhuǎn)編碼器檢測(cè)排種器實(shí)時(shí)轉(zhuǎn)速。控制決策系統(tǒng)將排種器理論轉(zhuǎn)速和排種器實(shí)時(shí)轉(zhuǎn)速作為輸入量，通過遺傳算法對(duì)PID參數(shù)進(jìn)行整定，得到排種器目標(biāo)轉(zhuǎn)速，然后調(diào)節(jié)控制器輸出相應(yīng)的PWM占空比，進(jìn)而調(diào)節(jié)施加在電動(dòng)機(jī)電樞兩端的平均電壓，達(dá)到調(diào)節(jié)電動(dòng)機(jī)轉(zhuǎn)速、實(shí)現(xiàn)精密排種的目的。

圖1 電控排種系統(tǒng)作業(yè)原理框圖Fig.1 Schematic of electronic control seeding system

2 電動(dòng)機(jī)調(diào)速系統(tǒng)數(shù)學(xué)模型

2.1 播種作業(yè)速度與排種器轉(zhuǎn)速的關(guān)系

選擇玉米勺輪式排種器為研究對(duì)象，設(shè)有m個(gè)種勺，則相鄰2粒種子的落地時(shí)間差為

(1)

式中 Δt——相鄰2粒種子落地時(shí)間差，sn——排種盤轉(zhuǎn)速，r/min

株距為

(2)

式中Z——玉米株距，mmv——拖拉機(jī)行走速度，km/h

本次設(shè)計(jì)中m=18，代入式(2)可得

(3)

2.2 電動(dòng)機(jī)調(diào)速系統(tǒng)傳遞函數(shù)

電控排種系統(tǒng)主要是實(shí)現(xiàn)電動(dòng)機(jī)轉(zhuǎn)速的控制，實(shí)際上也是一個(gè)無(wú)刷直流電動(dòng)機(jī)的控制系統(tǒng)。假設(shè)電動(dòng)機(jī)在理想狀態(tài)下進(jìn)行工作，由電動(dòng)機(jī)學(xué)理論可得無(wú)刷直流電動(dòng)機(jī)的微分方程式為[24-26]

(4)

式中Td——電磁時(shí)間常數(shù)Tm——機(jī)電時(shí)間常數(shù)n1——電動(dòng)機(jī)轉(zhuǎn)速Ce——電動(dòng)機(jī)反電動(dòng)勢(shì)系數(shù)U0——電樞電壓

對(duì)式(4)進(jìn)行拉氏變換，得電動(dòng)機(jī)的傳遞函數(shù)為

(5)

選用80系列無(wú)刷直流電動(dòng)機(jī)，其主要參數(shù)為：Tm=0.9 s，Td=8.1 ms，Ce=11.7 V/(r/min)，代入式(5)后可得

(6)

3 控制器控制策略

3.1 基于Ziegler-Nichols階躍響應(yīng)法的PID參數(shù)整定

控制系統(tǒng)的設(shè)計(jì)關(guān)鍵是實(shí)現(xiàn)對(duì)電動(dòng)機(jī)的控制，所以電動(dòng)機(jī)的傳遞函數(shù)即系統(tǒng)的傳遞函數(shù)。通過Matlab中的Ziegler-Nichols程序得到系統(tǒng)傳遞函數(shù)的根軌跡圖形，如圖2所示。

圖2 電動(dòng)機(jī)調(diào)速系統(tǒng)傳遞函數(shù)根軌跡圖形Fig.2 Root locus graph of motor speed system transfer function

由圖2可得開環(huán)增益Zm=21.057 dB，穿越頻率Wm=84.96 Hz。根據(jù)PID整定公式得

(7)

式中KP——比例系數(shù)KI——積分系數(shù)KD——微分系數(shù)

將式(7)的3個(gè)參數(shù)分別輸入系統(tǒng)PID控制器的Simulink模型中，得仿真結(jié)果如圖3所示。

圖4 控制系統(tǒng)Simulink模型Fig.4 Simulink model of control system

圖3 由Ziegler-Nichols階躍響應(yīng)法整定PID參數(shù)的仿真結(jié)果Fig.3 Simulation results of PID parameters by Zieglor-Nichols step response method

由仿真結(jié)果可以看出，應(yīng)用Ziegler-Nichols階躍響應(yīng)法整定的PID參數(shù)雖然能使控制系統(tǒng)趨于穩(wěn)定，但超調(diào)量大，所以仍需對(duì)PID參數(shù)進(jìn)行優(yōu)化整定。遺傳算法可以在初始條件選擇不當(dāng)?shù)那闆r下，仍能尋求合適的參數(shù)，而且避免了大量的專家經(jīng)驗(yàn)和知識(shí)庫(kù)整理工作，因此本文應(yīng)用遺傳算法對(duì)PID參數(shù)進(jìn)行優(yōu)化。

3.2 遺傳算法的PID參數(shù)優(yōu)化整定

由Ziegler-Nichols階躍響應(yīng)法整定的PID參數(shù)確定遺傳算法中PID參數(shù)KP、KI、KD的取值范圍分別為[0，20]、[0，350]、[0，1]，采用二進(jìn)制編碼方式對(duì)3個(gè)參數(shù)進(jìn)行編碼。為了避免超調(diào)，采用了懲罰功能，最優(yōu)指標(biāo)函數(shù)選為

(8)

式中w1、w2、w3、w4——權(quán)值，且w4?w1e(t)——系統(tǒng)誤差u(t)——控制器輸出ey(t)——兩次采樣時(shí)間間隔系統(tǒng)輸出誤差

tu——上升時(shí)間

建立控制系統(tǒng)的Simulink模型如圖4所示。本次設(shè)計(jì)中，遺傳算法各參數(shù)取值為：w1=0.999，w2=0.001，w3=1，w4=100，種群規(guī)模N=30，交叉概率Pc=0.9，變異概率隨機(jī)且小于0.5。

經(jīng)過100代進(jìn)化后，代價(jià)函數(shù)J-1的優(yōu)化過程如圖5所示。優(yōu)化后可得各參數(shù)如下：J-1=5.046 2，KP=1.289 4，KI=0.769 2，KD=0.002。將優(yōu)化后的PID參數(shù)代入Simulink模型中進(jìn)行仿真，得到由遺傳算法整定的PID參數(shù)的仿真曲線如圖6所示。由仿真結(jié)果可得，將遺傳算法整定的PID參數(shù)應(yīng)用于電控排種器控制，系統(tǒng)無(wú)超調(diào)，通過軟件中的坐標(biāo)標(biāo)識(shí)可得調(diào)節(jié)時(shí)間為0.25 s。

圖5 代價(jià)函數(shù)J-1的優(yōu)化過程Fig.5 Cost function J-1 optimization process

圖6 遺傳算法整定的PID參數(shù)仿真結(jié)果Fig.6 Simulation results of PID parameters based onLJ optimal algorithm

4 控制系統(tǒng)設(shè)計(jì)

4.1 硬件設(shè)計(jì)

控制系統(tǒng)主要由硬件和軟件組成，其中硬件主要由電源模塊、信號(hào)采集模塊、控制模塊、電動(dòng)機(jī)驅(qū)動(dòng)模塊、排種執(zhí)行模塊和人機(jī)交互模塊組成。其中電源模塊在田間試驗(yàn)時(shí)采用逆變器將拖拉機(jī)自帶電源的12 V轉(zhuǎn)換為48 V供控制系統(tǒng)使用；電動(dòng)機(jī)驅(qū)動(dòng)模塊中，由于電動(dòng)機(jī)轉(zhuǎn)速過高，設(shè)計(jì)時(shí)根據(jù)排種器作業(yè)轉(zhuǎn)速限制選用速比為40的減速器；為便于排種器、電動(dòng)機(jī)、減速器和編碼器的安裝，設(shè)計(jì)時(shí)對(duì)排種軸進(jìn)行了改進(jìn)，安裝方式如圖7所示；信號(hào)采集模塊中，應(yīng)用雷達(dá)測(cè)速儀的多普勒效應(yīng)，通過采集發(fā)射與接收的頻率差來(lái)檢測(cè)播種作業(yè)速度，其安裝方式如圖8所示。硬件配置表和控制系統(tǒng)電路圖分別如表1和圖9所示。

圖7 排種執(zhí)行模塊Fig.7 Metering executable module

圖8 雷達(dá)測(cè)速儀安裝方式Fig.8 Installation mode of radar speed device

設(shè)備名稱規(guī)格型號(hào)雷達(dá)測(cè)速儀美國(guó)帝強(qiáng)RadarIII編碼器38T8G524E1000BL1T2m電動(dòng)機(jī)驅(qū)動(dòng)器直流無(wú)刷驅(qū)動(dòng)器ZM6615顯示屏TFTLCDILI9341在線調(diào)試器STLINKV2電壓轉(zhuǎn)換模塊XW36481260W開關(guān)式直流穩(wěn)壓器電平信號(hào)轉(zhuǎn)換器HCPL2630雙通道邏輯輸出光電耦合器

圖9 控制系統(tǒng)電路圖Fig.9 Circuit diagram of control system

4.2 軟件設(shè)計(jì)

控制系統(tǒng)軟件設(shè)計(jì)選用Keil μ Vision 5作為開發(fā)環(huán)境，應(yīng)用C語(yǔ)言進(jìn)行編程，系統(tǒng)控制流程圖如圖10所示。

圖10 控制系統(tǒng)流程圖Fig.10 Flow chart of control system

圖11 田間試驗(yàn)Fig.11 Field experiment

5 試驗(yàn)與結(jié)果分析

5.1 控制精度性能試驗(yàn)

試驗(yàn)材料選用中單909玉米雜交種，試驗(yàn)在安徽農(nóng)業(yè)大學(xué)工學(xué)院試驗(yàn)田進(jìn)行，整機(jī)實(shí)物圖和田間試驗(yàn)如圖11所示。試驗(yàn)地塊長(zhǎng)20 m，每次試驗(yàn)采集平穩(wěn)作業(yè)后的60個(gè)數(shù)據(jù)，重復(fù)3次，結(jié)果取平均值。以不同作業(yè)工況下的排種器理論轉(zhuǎn)速和實(shí)時(shí)轉(zhuǎn)速為檢測(cè)對(duì)象，比較兩者之間的差值大小，作為控制精度。試驗(yàn)結(jié)果如圖12所示。

圖12 不同作業(yè)工況下機(jī)具部分運(yùn)動(dòng)參數(shù)變化曲線Fig.12 Variation curves of machine’s some motion parameters in different driving cycles

圖12中的PWM值表示在0～900范圍內(nèi)調(diào)節(jié)細(xì)分?jǐn)?shù)從而實(shí)現(xiàn)調(diào)節(jié)占空比由0～1的變化。以排種器理論轉(zhuǎn)速和實(shí)時(shí)轉(zhuǎn)速為分析對(duì)象，分析結(jié)果見表2。由圖13和表2可以看出，在播種作業(yè)開始和停止階段，排種器理論轉(zhuǎn)速和實(shí)時(shí)轉(zhuǎn)速偏差較大；當(dāng)播種作業(yè)于穩(wěn)定階段時(shí)，平均誤差的最大值為8.02%，最小值為2.32%，控制精度高；各播種作業(yè)工況中，以中高速行駛(8 km/h

表2 不同作業(yè)工況下排種器理論轉(zhuǎn)速和實(shí)際轉(zhuǎn)速誤差Tab.2 Analysis of theoretical speed and actual speed of metering device in different driving cycles

圖13 電控播種和傳統(tǒng)播種在不同作業(yè)工況下的合格指數(shù)平均值對(duì)比Fig.13 Comparison of average qualified index under different working conditions by electronic control and traditional sowing

5.2 排種性能試驗(yàn)

試驗(yàn)參照GB/T 6973—2005《單粒(精密)播種機(jī)試驗(yàn)方法》，選擇合格指數(shù)、重播指數(shù)、漏播指數(shù)和粒距變異系數(shù)為排種性能指標(biāo)。試驗(yàn)統(tǒng)計(jì)結(jié)果如表3所示。

由圖13和圖14可以看出，應(yīng)用該電控排種系統(tǒng)進(jìn)行田間玉米播種作業(yè)時(shí)，排種合格指數(shù)平均值為92.40%，與作者前期對(duì)傳統(tǒng)排種研究的合格指數(shù)88.77%相比提高3.63個(gè)百分點(diǎn)[27]；漏播指數(shù)平均值為4.82%(除去個(gè)別由田間復(fù)雜工況出現(xiàn)的突變情況外)，與作者前期對(duì)傳統(tǒng)排種研究的漏播指數(shù)6.86%降低2.04個(gè)百分點(diǎn)。

由圖15和圖16可以看出，當(dāng)遞種起始角為29°時(shí)，應(yīng)用該電控排種控制系統(tǒng)在中高速播種作業(yè)下效果較其它作業(yè)工況差；但所有播種作業(yè)工況下粒距變異系數(shù)均小于4.2%，播種效果好。

表3 不同作業(yè)工況和不同遞種起始角下的排種性能統(tǒng)計(jì)結(jié)果Tab.3 Statistic results of seed performance under different working conditions and different start delivery angles

圖14 電控播種和傳統(tǒng)播種在不同作業(yè)工況下的漏播指數(shù)平均值對(duì)比Fig.14 Comparison of average miss index under different working conditions by electronic control and traditional sowing

6 結(jié)論

(1)針對(duì)現(xiàn)有播種控制系統(tǒng)設(shè)計(jì)時(shí)存在的速度采集誤操作問題和精準(zhǔn)農(nóng)業(yè)要求，設(shè)計(jì)了一款電控排種器，建立了相應(yīng)的傳遞函數(shù)與Simulink模型，并基于遺傳算法進(jìn)行了PID參數(shù)的整定和控制器設(shè)計(jì)，提高了控制精度。

圖15 不同遞種起始角與不同播種作業(yè)工況下的排種合格指數(shù)Fig.15 Sowing qualified index under different working conditions and different start delivery angles

圖16 不同遞種起始角與不同作業(yè)工況下的粒距變異系數(shù)Fig.16 Maize distance variation coefficient under different working conditions and different start delivery angles

(2)試驗(yàn)結(jié)果表明，應(yīng)用該電控排種系統(tǒng)進(jìn)行田間玉米播種作業(yè)時(shí)，排種合格指數(shù)平均值為92.40%，與傳統(tǒng)排種相比提高3.63個(gè)百分點(diǎn)；漏播指數(shù)平均值為4.82%，與傳統(tǒng)排種相比降低2.04個(gè)百分點(diǎn)；不同播種作業(yè)工況下的粒距變異系數(shù)均小于4.20%，播種效果好。

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Design and Test of Electronic Control Seeding System for Maize

ZHANG Chunling1,2WU Rong1CHEN Liqing1

(1.SchoolofEngineering,AnhuiAgriculturalUniversity,Hefei230036,China2.CollegeofEngineering,HuazhongAgriculturalUniversity,Wuhan430070,China)

When the traditional maize seeder works in the field, the power of seed metering device comes from ground steel. Aiming at the problem that the field conditions are so complicated that the ground steel will skid easily, then the miss index will be increased, an electronic maize sowing control system was designed. The police traffic radar collected the sowing operation speed when the sowing was started, then the control system will calculate the seed metering device rotational speed combined with the theoretical particle distance. The rotary encoder collected the seed metering device rotational speed, then the controller would process speed based on control strategy and obtained the last speed. The optimal process of control strategy can improve the accuracy. The results of the field test showed that when the electronic control seed metering device was working in the field, the average qualified index was 92.40%, which was increased by 3.63 percentage points compared with the traditional sowing. The average miss index was 4.82% and it was reduced by 2.04 percentage points compared with the traditional sowing. The variability of seed-spaces was less than 4.20% and the sowing effects were much more than the national standard. When the speed of sowing was more than 10km/h, the effects was worse than other cases, therefore some improvement on the structure to improve the accuracy. The design of the electronic control maize seed metering device provided some definite reference for study of sowing control system.

precision maize planter; electronic control; seeding system

10.6041/j.issn.1000-1298.2017.02.007

2016-06-29

2016-10-08

農(nóng)業(yè)部公益性行業(yè)專項(xiàng)(201503136)和安徽省科技攻關(guān)項(xiàng)目(1501031104)

張春嶺(1989—)，男，助教，華中農(nóng)業(yè)大學(xué)博士生，主要從事精細(xì)農(nóng)業(yè)理論技術(shù)與裝備研究，E-mail： ZCL158967592@163.com

陳黎卿(1979—)，男，教授，博士，主要從事玉米播種和秸稈處理類機(jī)械設(shè)計(jì)研究，E-mail： lqchen@ahau.edu.cn

S223.2

A

1000-1298(2017)02-0051-09