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受控风阻式西瓜低损翻筐上料装备设计与试验

Airflow-Resisted flexible tilting feeding system for fruits: Design and mechanism

  • 摘要: 针对西瓜类大型水果在分级包装自动化上料过程中冲击大、易损伤的问题,提出一种基于电子西瓜模型碰撞强度采集的受控风阻式柔性翻筐上料方法。以电子西瓜模型作为农业物料碰撞感知载体,对上料过程中水果运动与冲击特性进行实时采集与量化分析,并据此构建“物料运动-碰撞感知-气流调控”协同设计方法。设计直线-圆弧复合导轨翻筐机构,实现周转筐由竖直提升到倾翻卸料的连续过渡;构建翻筐卸料区域可调气流场,建立西瓜在重力与空气阻力共同作用下的运动模型,并提出基于翻筐角度与物料状态演化的分阶段风阻调控策略,实现翻筐运动与气流场的动态耦合控制。风机转速在4 000~3 6000 r/min范围内调节时,可形成稳定可控的气流缓冲场;在风阻调控条件下,西瓜冲击峰值加速度由33.34 m/s2降低至19.32 m/s2,冲击降低率为42.1%,果蔬运动状态由集中塌落转变为缓慢滑移与分散释放。真实西瓜试验中,无风阻组和有风阻组各组重复累计上料75果次,分别裂果4颗和1颗,按果次统计的裂果率分别为5.33%和1.33%,有风阻组相对降低4.00%。所提出方法能够在保证上料效率的同时有效降低大型水果机械损伤风险,为农业物料低损自动化处理装备设计提供参考。

     

    Abstract: Large fruits such as watermelons are easily damaged during automated grading, packaging and transfer operations because the fruit container is usually lifted and tipped as a whole, causing the fruit group to roll, collapse and collide with the receiving surface. To reduce this impact while maintaining continuous feeding, a controlled air-resistance flexible tipping-bucket feeding method based on collision sensing with an electronic watermelon model was proposed. The electronic watermelon model was used as a collision-sensing carrier with a size, mass and bulk density close to those of commercial watermelon. It collected acceleration and attitude information during the whole feeding process, and the resultant linear acceleration after gravity removal was used to quantify the impact response of the fruit group. On this basis, a collaborative design framework of material motion, collision sensing and airflow regulation was established. A linear-arc composite guide-rail tipping mechanism was designed to realize a continuous transition of the fruit container from vertical lifting to tipping discharge. The kinematic relationship between bucket angle, roller position and fruit motion stage was analyzed, and an adjustable airflow field was arranged in the unloading region. A motion model of watermelon under the combined action of gravity and air resistance was established to explain how the upward and lateral aerodynamic forces reduce the falling velocity and disperse the concentrated collapse of fruit. According to the evolution of bucket angle and material state, the feeding process was divided into lifting, transition, rolling-sliding, collapse and outflow stages. A staged air-resistance regulation strategy was then proposed: the fan was kept off or at a low output during the stable lifting and transition stages, a higher duty cycle was used during the rolling-sliding stage to suppress rapid acceleration, a medium duty cycle was used during the collapse stage to reduce concentrated impact, and the airflow was reduced during the outflow stage to avoid fruit retention. Experiments were carried out on a tipping-bucket feeding platform. The fan speed, wind speed and thrust were measured under different duty cycles, and the collision response of the electronic watermelon model was compared under different spatial positions, fan duty cycles and staged control conditions. The results showed that fan speed increased approximately linearly with PWM duty cycle, while thrust increased nonlinearly with speed. A stable and controllable airflow buffering field was formed when the fan speed was adjusted within approximately 4,000–36,000 r/min. Without sufficient airflow, the fruit group was prone to concentrated collapse, and high impact peaks occurred mainly near the rear side of the container. With air-resistance regulation, the material motion changed from rapid rolling and concentrated collapse to slower sliding and dispersed release. The peak impact acceleration decreased from 33.34 m/s2to 19.32 m/s2 when the duty cycle increased from 20% to 80%, corresponding to a reduction rate of 42.1%. In repeated tests with real watermelons, the groups without and with air resistance each completed 75 cumulative fruit passes. Four fruits cracked in the group without air resistance and one in the group with air resistance. The corresponding cracking rates per fruit pass were 5.33% and 1.33%, respectively, an absolute decrease of 4.00 percentage points. The staged control strategy further improved the coordination between tipping motion and airflow output, reducing severe impact while keeping the discharge process continuous. The study indicates that controlled airflow can be used as an active flexible buffer for large-fruit feeding equipment. The proposed method can reduce the risk of mechanical damage to large fruits while maintaining feeding efficiency and provides a reference for the design of automated equipment for handling agricultural materials with low damage.

     

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