Do 16_15h Wöbcke
Transcrição
Do 16_15h Wöbcke
Faculty of Mechanical Engineering Chair Agricultural Systems and Technology Electrical drive train for combine headers Elektrifiziertes Antriebssystem für Getreideschneidwerke Steffen Wöbcke, Thomas Herlitzius P. Hornberger, N. Michalke, F. Mörtl, M. Müller, U. Schuffenhauer, J. Seyfarth VDI-MEG Kolloquium Mähdrescher, Hohenheim, 12./13.September 2013 Content I. Introduction and description of initial state II. Objectives of electrifying a combine header III. System design IV. Benefits of electrified headers V. Summary and outlook September 12, 2013 VDI-MEG Kolloquium Mähdrescher Slide 2 Introduction requirements of global market are increasing productivity with decreasing harvesting costs and increasing profitableness in past meeting requirements by improving functionality increasing diesel engine power increasing harvesting ground speed increasing header width image source: Zürn proposition: continuing increasing combine productivity by using function-specific, distributed, modular designed drives new drive concepts, optimized in available space, energy-efficiency automation of operating sequences September 12, 2013 VDI-MEG Kolloquium Mähdrescher Slide 3 Initial state main header assemblies knife intake auger reel feeder belts (optional) lateral knives feeder belts intake auger knife lateral knives reel image sources: ACGO, Claas, Geringhoff September 12, 2013 VDI-MEG Kolloquium Mähdrescher Slide 4 Initial state knife: belt, gearbox with shafts or hydraulic motor, cutting width > 9 m: divided cutterbar with twosided drive, fixed speed intake auger: chain or gearbox and overload clutch, one-sided drive, fixed speed reel: hydraulic motor or belt variator, one-sided drive, variable speed feeder belts (optional): chain, fixed speed lateral knives: hydraulic, electrical or mechanical image sources: Claas, Geringhoff, Zürn September 12, 2013 VDI-MEG Kolloquium Mähdrescher Slide 5 Objectives of electrifying combine headers reel intake auger knife intake belts variability of speed available - - - separate reversing - - - - adjustable torque limits - - - - sensor system n [min-1], M [Nm] - - - - September 12, 2013 VDI-MEG Kolloquium Mähdrescher Slide 6 Objectives of electrifying combine headers reel intake auger knife intake belts variability of speed available desired desired desired separate reversing desired desired - desired adjustable torque limits desired desired desired - sensor system n [min-1], M [Nm] desired desired desired desired technical solution meeting demands best: electrical drives September 12, 2013 VDI-MEG Kolloquium Mähdrescher Slide 7 Experimental platform experimental model: header Zürn 640 PF 40 ft (12 m) knife: belt with planetary drive, two-sided drive, fixed speed intake auger: chain drive and friction clutch, one-sided drive, fixed speed reel: hydraulic motor, middle drive, variable speed feeder belts: 8 belts chain drive, one-sided drive, fixed speed lateral knives: mechanical knife intake auger reel image source: Zürn lateral knives feeder belts drives in combine header September 12, 2013 VDI-MEG Kolloquium Mähdrescher Slide 8 Nominal power requirements 40 ft header for dimensioning speed [min-1] torque [Nm] power [kW] knife 600 250 15,7 reel 40 1500 6,3 intake belts 385 120 4,8 intake auger 260 1000 27,2 lateral knives 550 17 1 component sum 55,0 image source: Zürn September 12, 2013 VDI-MEG Kolloquium Mähdrescher Slide 9 Design of electrical system closed system of generation, transformation, storage, transfer and management standard connection to combine: drive shaft electric / CANBUS own generator on header DC link own cooling circuit September 12, 2013 VDI-MEG Kolloquium Mähdrescher Slide 10 Design of electrical system electrical system on header voltage level 58 V DC in DC link (extra low voltage, below threshold of 60 V) advantages: no additional safety equipment required (e.g. insulation monitor) legal regulations: even no protection against creature contact necessary reduced effort for EMC disadvantage: higher dimension of cable cross-section image source: Compact Dynamics September 12, 2013 VDI-MEG Kolloquium Mähdrescher Slide 11 Design of electrical system knife: divided cutterbar with 2 drives variable speed intake auger: two-sided drive, 2 electric motors partly integrated in auger variable speed reel: one-sided drive, 1 electric motor partly integrated in reel variable speed feeder belts: 8 belts every belt with own electric motor partly integrated between belts variable speed lateral knives: left and right side mechanical drive alternative electric motors image source: Compact Dynamics September 12, 2013 VDI-MEG Kolloquium Mähdrescher Slide 12 Design of electrical system technical data of main used electric machine Dynax in header inverter 3-phase inverter integrated voltage DC 42 V – 58 V power (continuous) 20 kW (at 58 VDC) power (maximum) 25 kW (at 58 VDC) torque 75 Nm (up to 3000 min-1) maximum speed 10.000 min-1 cooling water / glycol weight 14 kg number of Dynax machines in header: generators (3) intake auger (2) reel (1) knife (2) efficiency of motor and inverter 242 torque [Nm] ∅ 250 174 speed [1/min] September 12, 2013 VDI-MEG Kolloquium Mähdrescher image source: Compact Dynamics Slide 13 Design of electrical system challenges of function-specific, distributed, modular designed drives in comparison to all-mechanical drives specific loads become more important removal of inertia decoupling of diesel engine’s and combine’s inertia system linear sinusoidal trajectory of cutterbar and load cycle of electric motor simulation provides conclusions for dimensioning and design of drive system strategy for control mechanical loads power distribution linear force and drive power 1 1,0 0,8 0,6 M/Mmax 0,2 0,0 -0,2 0 10 20 30 40 50 60 70 -0,4 -0,6 80 F*/Fmax, P*/Pn 0,5 0,4 0 0,25 0,3 0,35 0,4 0,45 0,5 -0,5 -0,8 F, variant 1 P, variant 1 F, variant 2 -1,0 stroke [mm] -1 forward stroke - acceleration forward stroke - deceleration return stroke - acceleration return stroke - deceleration September 12, 2013 VDI-MEG Kolloquium Mähdrescher t in s P, variant 2 Slide 14 Benefits of electrified headers I additional benefit caused by advantages of electrical drives decentralized drives are mostly integrated into functional elements reduced space demands especially in side panel sections enhanced maneuverability at barriers and headland reduced crossing crop and reduced header losses advantages of electrical drives in headers: variable speed absolute value direction adjustable torque limits integrated measurement of current and voltage calculation of speed and torque possible image source: Zürn September 12, 2013 VDI-MEG Kolloquium Mähdrescher Slide 15 Benefits of electrified headers II homogenized crop flow in header and in combine increased feedrate of combine at constant loss level reduced cleaning and separation losses at constant feedrate generation of feedrate related signal for feedrate control of combine reduced wear and tear of drives and functional elements reduction of maintenance reduced costs image source: Wikipedia September 12, 2013 VDI-MEG Kolloquium Mähdrescher Slide 16 Benefits of electrified headers III opportunity of separate reversing functional elements fast removal of jamming crop reduced machine downtime and increased combine performance condition monitoring of functional elements generation of load cycles maintenance interval load-dependent instead of time-dependent reduction of maintenance reduced machine downtime reduced costs image sources: Schumacher, agrartechnik-im-einsatz September 12, 2013 VDI-MEG Kolloquium Mähdrescher Slide 17 Benefits of electrified headers IV new form of power-train management system semi-automated header functions reduced excessive demands of operator, especially homogenizing crop flow in header and in combine fast removal of jamming crop image source: John Deere September 12, 2013 VDI-MEG Kolloquium Mähdrescher Slide 18 Challenges of electrified header challenges of electrical drive system in combine headers costs of electrical drives complexity generating electrical energy EMC cooling system … dynamic loads reliability of electrical components in field … September 12, 2013 VDI-MEG Kolloquium Mähdrescher Slide 19 Summary configuration of combine header with electrical drives generation of electrical energy with generators on header independent electrical and cooling system with same standard connection to combine as conventional headers drive train as decentralized architecture with torque and speed as degrees of freedom enhancement of functionality new strategies of power-train management system semi automated sequences possible image source: Zürn September 12, 2013 VDI-MEG Kolloquium Mähdrescher Slide 20 Outlook currently experiments on test stand field tests in season 2014 statements to technical feasibility and suitability of electrical drives in combine headers in field determination of power requirements and power distribution with available information as torque and speed load cycles can be deviated evaluation of additional benefit estimation of economic feasibility September 12, 2013 VDI-MEG Kolloquium Mähdrescher Slide 21 Thank you for your attention! website of project: www.eharvest.eu September 12, 2013 VDI-MEG Kolloquium Mähdrescher Slide 22