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Engineering Principles of Agricultural Machines: 2nd Edition
Engineering Principles of Agricultural Machines: 2nd Edition
Principles of
Agricultural
Machines
2nd Edition
Ajit K. Srivastava
Michigan State University
Carroll E. Goering
University of Illinois
Roger P. Rohrbach
North Carolina State University
Dennis R. Buckmaster
The Pennsylvania State University
Copyright 2006 by the
American Society of Agricultural and Biological Engineers
All rights reserved.
Reprinted June 2012 with editorial corrections.
Chapter 1
Agricultural Mechanization and Some Methods of Study 1
Introduction .............................................................................................................. 1
1.1 History of Mechanized Agriculture................................................................. 1
1.2 Farming Operations and Related Machines ................................................... 3
1.3 Functional Analysis of Agricultural Machines............................................... 4
1.3.1 Basic processes of agricultural machines................................................. 5
1.3.2 Process diagrams...................................................................................... 6
1.4 Dimensional Analysis ..................................................................................... 7
1.4.1 Scope........................................................................................................ 7
1.4.2 Physical dimensions................................................................................. 7
1.4.3 Units of measurement .............................................................................. 8
1.4.4 Developing a prediction equation ............................................................ 9
1.4.5 Buckinghams Theorem......................................................................... 10
1.4.6 Systematic calculation of the dimensionless products ............................. 12
1.4.7 Transformation of dimensionless products ............................................ 13
Problems ................................................................................................................. 14
Chapter 2
Engine Power for Agricultural Machines 15
Introduction ............................................................................................................ 15
2.1 The power in fuel .......................................................................................... 15
2.2 Combustion ................................................................................................... 16
2.2.1 Combustion chemistry ........................................................................... 16
2.2.2 Energy release in combustion ................................................................ 19
2.3 Thermodynamic limits to Engine Performance............................................ 21
2.4 Heat Losses and Power at the Pistons .......................................................... 25
2.5 Mechanical Losses and Power at the Flywheel............................................. 26
2.6 Engine Torque and Efficient Engine Loading.............................................. 28
2.7 Control of Engine Speed ............................................................................... 29
2.8 Engine performance simulator ..................................................................... 33
2.9 Turbocharging and Intercooling Engines ..................................................... 35
2.9.1 Operation of turbochargers .................................................................... 36
2.9.2 Intercoolers ............................................................................................ 39
viii CONTENTS
Chapter 3
Electrical Power for Agricultural Machines 45
Introduction ............................................................................................................ 45
3.1 Motor Components........................................................................................ 45
3.2 Motor Classifications .................................................................................... 46
3.3 Principles of Operation Of Induction Motors............................................... 47
3.4 Types of Single-Phase Induction Motors ..................................................... 49
3.4.1 Split-phase induction motors.................................................................. 49
3.4.2 Capacitor-start, induction-run motors .................................................... 50
3.4.3 Two-value-capacitor, induction-run motors........................................... 52
3.4.4 Repulsion-start, induction-run motors.................................................... 52
3.5 Three-Phase Induction Motors ..................................................................... 53
3.6 Dual-Voltage Motors .................................................................................... 54
3.7 Torque-Speed Characteristics of Induction Motors....................................... 56
3.8 Motor Nameplate Information ..................................................................... 57
3.9 Motor Starters ............................................................................................... 59
3.10 Motor Enclosures .......................................................................................... 59
3.11 Variable- Speed Electric Motors .................................................................. 59
3.12 Motor Efficiency ........................................................................................... 60
Problems ................................................................................................................. 61
Simulation Problems............................................................................................... 63
Chapter 4
Mechanical Power Transmission 65
Introduction ............................................................................................................ 65
4.1 V-Belt Drives ................................................................................................ 65
4.1.1 V-belt types and standardization............................................................ 66
4.1.2 V-belt drive geometry ............................................................................ 67
4.1.3 Kinematics of V-belt drives ................................................................... 68
4.1.4 Mechanics of V-belt drives .................................................................... 69
4.1.5 Stresses and service life ......................................................................... 72
4.1.6 Variable-speed V-belt drives.................................................................. 74
4.1.7 V-belt drive design................................................................................. 76
4.2 Chain Drives ................................................................................................. 76
4.2.1 Types of chains and standardization ...................................................... 76
4.2.2 Geometry of chain drives....................................................................... 79
4.2.3 Kinematics of chain drives..................................................................... 79
4.2.4 Design of chain drives............................................................................ 82
ENGINEERING PRINCIPLES OF AGRICULTURAL MACHINES ix
Chapter 5
Fluid power, mechatronics, and control 91
Introduction ............................................................................................................ 91
5.1 Basic Principles and Elements Of Fluid Power............................................ 91
5.2 Pumps............................................................................................................ 92
5.3 Valves ........................................................................................................... 96
5.3.1 Pressure control valves........................................................................... 96
5.3.2 Volume control valves ........................................................................... 98
5.3.3 Directional control valves ...................................................................... 99
5.4 Actuators ..................................................................................................... 102
5.4.1 Hydraulic motors ................................................................................. 102
5.4.2 Hydraulic cylinders .............................................................................. 102
5.5 Reservoirs, Fluids, Filters, and Lines ......................................................... 104
5.6 Types of Fluid Power Systems................................................................... 107
5.6.1 Open-center systems ............................................................................ 107
5.6.2 Pressure-compensated systems ............................................................ 109
5.6.3 Load-sensing systems .......................................................................... 109
5.7 Pressure Transients...................................................................................... 111
5.8 Hydrostatic Transmissions .......................................................................... 112
5.9 Mechatronics and System Control ............................................................. 114
5.9.1 An introduction to mechatronics.......................................................... 114
5.9.2 System control ..................................................................................... 115
Problems ............................................................................................................... 117
Simulation Problems............................................................................................. 121
Chapter 6
Precision agriculture 123
Introduction .......................................................................................................... 123
6.1 Sensors ........................................................................................................ 124
6.1.1 Sensor types ......................................................................................... 124
6.1.2 Sensor applications .............................................................................. 124
6.1.3 Advanced sensors................................................................................. 124
6.2 Global Positioning System .......................................................................... 125
6.2.1 GPS for civilian use ............................................................................. 125
6.2.2 Military GPS ........................................................................................ 125
x CONTENTS
Chapter 7
Tractor Hitching, Traction, and Testing 139
Introduction .......................................................................................................... 139
7.1 Hitching Systems ........................................................................................ 139
7.1.1 Principles of hitching ........................................................................... 139
7.1.2 Types of hitches ................................................................................... 139
7.1.3 Hitching and weight transfer................................................................ 142
7.1.4 Control of hitches................................................................................. 144
7.2 Tires and Traction ....................................................................................... 144
7.2.1 Basic tire design................................................................................... 146
7.2.2 Traction models ................................................................................... 149
7.2.3 Traction predictor spreadsheet ............................................................. 153
7.3 Soil Compaction.......................................................................................... 154
7.4 Traction Aids............................................................................................... 155
7.5 Tractor Testing ............................................................................................ 156
7.5.1 Basic principles of tractor testing......................................................... 156
7.5.2 Official tractor tests.............................................................................. 158
Problems ............................................................................................................... 165
Simulation Problems............................................................................................. 166
Chapter 8
Soil Tillage 169
Introduction .......................................................................................................... 169
ENGINEERING PRINCIPLES OF AGRICULTURAL MACHINES xi
Chapter 9
Crop Planting 231
Introduction .......................................................................................................... 231
9.1 Methods and Equipment ............................................................................. 231
9.1.1 Broadcast seeding ................................................................................ 231
9.1.2 Drilling................................................................................................. 232
9.1.3 Precision planting................................................................................. 233
9.1.4 Transplanting ....................................................................................... 234
9.2 Functional Processes ................................................................................... 235
9.2.1 Seed metering....................................................................................... 235
9.2.2 Seed transport....................................................................................... 245
9.2.3 Furrow opening and covering .............................................................. 255
9.2.4 Transplanting ....................................................................................... 258
9.3 Evaluating Planter and Transplanter Performance ...................................... 262
9.3.1 Broadcast seeders................................................................................. 262
9.3.2 Drills .................................................................................................... 264
9.3.3 Precision planters ................................................................................. 264
9.3.4 Transplanters........................................................................................ 265
Problems ............................................................................................................... 265
xii CONTENTS
Chapter 10
Chemical Application 269
Introduction .......................................................................................................... 269
10.1 Application of Granular Chemicals............................................................ 269
10.1.1 Methods for application of granular chemicals.................................... 270
10.1.2 Equipment for application of granular chemicals ................................ 270
10.1.3 Functional processes of granular chemical applications ..................... 273
10.2 Application of Liquid Chemicals ............................................................... 280
10.2.1 Methods for application of liquid chemicals........................................ 280
10.2.2 Equipment for application of liquid chemicals .................................... 280
10.2.3 Functional processes of applying liquid chemicals .............................. 286
10.3 Performance Evaluation .............................................................................. 310
10.3.1 Uniformity of coverage of granular chemical application .................. 310
10.3.2 Calibration of fertilizer spreaders......................................................... 312
10.3.3 Liquid chemical application................................................................. 315
10.3.4 Sprayer calibration ............................................................................... 321
Problems ............................................................................................................... 322
Chapter 11
Hay and Forage Harvesting 325
Introduction .......................................................................................................... 325
11.1 Methods and Equipment ............................................................................. 325
11.2 Functional Processes ................................................................................... 331
11.2.1 Cutting mechanics and plant structure ................................................. 331
11.2.2 Cutting and chopping ........................................................................... 343
11.2.3 Curing and preservation of forage ........................................................ 370
11.2.4 Windrowing ......................................................................................... 374
11.2.5 Baling................................................................................................... 380
11.3 Performance Evaluation .............................................................................. 392
Problems ............................................................................................................... 395
Chapter 12
Grain Harvesting 403
Introduction .......................................................................................................... 403
12.1 Methods and Equipment ............................................................................. 403
12.1.1 Direct harvesting.................................................................................. 403
12.1.2 Cutting and windrowing....................................................................... 408
12.2 Functional Processes ................................................................................... 409
12.2.1 Gathering, cutting, pickup, and feeding ............................................... 410
12.2.2 Threshing ............................................................................................. 415
12.2.3 Separation ............................................................................................ 420
12.2.4 Cleaning ............................................................................................... 427
ENGINEERING PRINCIPLES OF AGRICULTURAL MACHINE xiii
Chapter 13
Fruit, Nut, and Vegetable Harvesting 437
Introduction .......................................................................................................... 437
Natural constraints ............................................................................................ 438
Economic constraints........................................................................................ 438
13.1 The Functional Processes ............................................................................ 439
13.1.1 Removal ............................................................................................... 439
13.1.2 Control ................................................................................................. 440
13.1.3 Selection............................................................................................... 440
13.1.4 Transportation ...................................................................................... 441
13.2 Methods and Equipment ............................................................................. 441
13.2.1 Root crops ............................................................................................ 442
13.2.2 Surface crops........................................................................................ 447
13.2.3 Bush and trellis crops........................................................................... 452
13.2.4 Tree crops............................................................................................. 459
13.3 Theoretical Considerations.......................................................................... 464
13.3.1 Aerodynamic concepts......................................................................... 464
13.3.2 Fundamentals of bush and tree shakers................................................ 468
13.3.3 Vibrational detachment during harvest ................................................ 475
13.3.4 Impact models and mechanical damage............................................... 476
13.4 Performance Factors.................................................................................... 483
13.4.1 Damage ................................................................................................ 484
13.4.2 Efficiency............................................................................................. 484
13.4.3 Reliability............................................................................................. 484
Problems ............................................................................................................... 486
Chapter 14
Conveying of Agricultural Materials 491
Introduction .......................................................................................................... 491
14.1 Screw Conveyors ........................................................................................ 491
14.1.1 Screw conveyor methods and equipment............................................. 491
14.1.2 Theory of screw conveyors .................................................................. 492
14.1.3 Screw conveyor performance............................................................... 494
14.2 Pneumatic Conveyors.................................................................................. 499
14.2.1 Pneumatic conveyor methods and equipment ...................................... 499
14.2.2 Theory of pneumatic conveyors........................................................... 502
14.2.3 Pneumatic conveyor performance........................................................ 510
14.3 Bucket Elevators ......................................................................................... 511
xiv CONTENTS
Chapter 15
Machinery Selection and Management 525
Introduction .......................................................................................................... 525
15.1 Field Capacity and Efficiency ..................................................................... 525
15.1.1 Field capacity ....................................................................................... 525
15.1.2 Field efficiency .................................................................................... 526
15.2 Draft and Power Requirements ................................................................... 529
15.3 Machinery Costs.......................................................................................... 535
15.3.1 Ownership costs ................................................................................... 535
15.3.2 Operating costs..................................................................................... 538
15.3.3 Timeliness costs ................................................................................... 540
15.4 Machinery Selection and Replacement......................................................... 545
15.4.1 Machinery selection ............................................................................. 545
15.4.2 Machinery replacement........................................................................ 548
Problems ............................................................................................................... 549
Simulation Problems............................................................................................. 551
Selected Bibliography.......................................................... 553
Appendix A............................................................................. 566
Appendix B .......................................................................... 568
Subject Index ...................................................................... 571