Do 16_15h Wöbcke

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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
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
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
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
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
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
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
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
Slide 10
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
Slide 11
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
September 12, 2013
Slide 12
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
Slide 13
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
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
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
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
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
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
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
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
Slide 21
Thank you for
your attention!
website of project:
www.eharvest.eu
September 12, 2013
Slide 22

Do 16_15h Wöbcke

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