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Development on electrical system performance test stand for combine harvester
Proceedings, 6th IFAC Conference on Bio-Robotics Proceedings, IFAC Conference onAvailable Bio-Robotics online at www.sciencedirect.com Beijing, China,6th July 13-15, 2018 Beijing, China,6th July 13-15, 2018 Proceedings, IFAC Conference on Bio-Robotics Beijing, China, July 13-15, 2018
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IFAC PapersOnLine 51-17 (2018) 363–367
Development on electrical system performance test stand Development on electrical system performance test stand for combine harvester Development on electrical system performance test stand for combine harvester for combine harvester
Dong Sun*. Du Chen**. Shumao Wang***. Xin Wang**** Dong Sun*. Du Chen**. Shumao Wang***. Xin Wang**** Dong Sun*. Du Chen**. Shumao Wang***. Xin Wang**** *College of Engineering, China Agricultural University, Beijing 100083, China *College of Engineering, China Agricultural University, Beijing 100083, China (email: [email protected]) *College of Engineering, (email: China Agricultural University, Beijing 100083, China [email protected]) ** College of Engineering, China Agricultural University, Beijing 100083, China [email protected]) ** College of Engineering,(email: China Agricultural University, Beijing 100083, China (Corresponding author, Tel: 86-10-62736591; email: [email protected]) ** (Corresponding College of Engineering, China Agricultural University, Beijing 100083, China author, Tel: 86-10-62736591; email: [email protected]) *** Beijing Key Laboratory of Optimized Design for Modern Agricultural Equipment, Beijing 100083, China (Corresponding author, Tel: 86-10-62736591; email: [email protected]) *** Beijing Key Laboratory of Optimized Design for Modern Agricultural Equipment, Beijing 100083, China (email: [email protected]) *** Beijing Key Laboratory of Optimized Design for Modern Agricultural Equipment, Beijing 100083, China (email: [email protected]) **** College of Engineering, China Agricultural University, Beijing 100083, China (email: [email protected]) **** College of Engineering, China Agricultural University, Beijing 100083, China (email: [email protected]) **** College of Engineering, China Agricultural University, Beijing 100083, China (email: [email protected]) (email: [email protected]) Abstract: Combine harvester is a large-scale multi-functional agricultural equipment integrating Abstract: Combine harvester is a large-scale multi-functional agricultural equipment integrating functions of picking, conveying, threshing and separating, and its working mechanism and electrical Abstract: ofCombine a large-scale multi-functional equipment functions picking, harvester conveying,isthreshing and separating, and its agricultural working mechanism andintegrating electrical system are complicated. According to statistics, when the harvesting machinery works in the field, the functions picking, conveying, and when separating, and its working mechanism electrical system areofcomplicated. Accordingthreshing to statistics, the harvesting machinery works in and the field, the fault of the electrical system accounts for about 30%, and there are even fire accidents caused by system According to statistics, when theand harvesting machinery in thecaused field, the fault ofare thecomplicated. electrical system accounts for about 30%, there are even fireworks accidents by electrical failures. Therefore, the harvester should comprehensively diagnose its electrical system fault of the electrical system accounts for about 30%, and there are diagnose even fire its accidents caused by electrical failures. Therefore, the harvester should comprehensively electrical system performance before leaving the the factory to improve the quality of the combined harvester and reduce the electrical failures. harvester should diagnose its electrical system performance before Therefore, leaving the factory to improve the comprehensively quality of the combined harvester and reduce the accident rate. In this paper, according to the needs of the detection of the combine harvester production performance the factorytotothe improve quality of theofcombined harvester and production reduce the accident rate.before In thisleaving paper, according needs the of the detection the combine harvester off-line, electrical detection parameters are proposed and an overall plan for the electrical system accident rate. In this paper, according to the needs of the detection of the combine harvester production off-line, electrical detection parameters are proposed and an overall plan for the electrical system performance test stand is formulated. The current and voltage detection methods are used to detect the off-line, electrical detection parameters proposed and andetection overall plan for are the used electrical system performance test stand is formulated. Theare current and voltage methods to detect the electrical parameters of the whole machine. The starting current curve evaluation method is used to performance test standofisthe formulated. The current voltage detection aremethod used to isdetect electrical parameters whole machine. The and starting current curve methods evaluation used the to detect the engine startup parameters. In order to verify the feasibility of the test stand, on-site verification electrical of parameters. the whole machine. starting current curve is used to detect the parameters engine startup In order toThe verify the feasibility of theevaluation test stand, method on-site verification tests were carried out on the combine harvester production line, and a comprehensive test was conducted detectwere the engine order to production verify the feasibility the test stand, test on-site tests carriedstartup out on parameters. the combineInharvester line, and aofcomprehensive wasverification conducted on the detection efficiency, static parameters, and dynamic parameter detection flow of the whole tests were carried out on the combine harvester production line, parameter and a comprehensive test was conducted on the detection efficiency, static parameters, and dynamic detection flow of the whole electrical system. Off-line tests showparameters, that the test stand can meet the rapid detection requirements of the on the detection efficiency, dynamic parameter flow of the whole electrical system. Off-line testsstatic show that the testand stand can meet the rapid detection detection requirements of the electrical system of the combined harvester production line, improve the detection efficiency. electrical system system.ofOff-line tests show that the test standline, can improve meet thethe rapid detection requirements of the the combined harvester production detection efficiency. electrical system of the combined harvester production line, improve the detection efficiency. © 2018, IFAC (International Federation of system; Automatic Control) Hosting virtual by Elsevier Ltd. Alloff-line rights reserved. Keywords: combine harvester; electrical quality inspection; instrument; detection; Keywords: combine harvester; electrical system; quality inspection; virtual instrument; off-line detection; Keywords: combine harvester; electrical system; quality inspection; virtual instrument; off-line detection; conditions, as well as a controlled combine harvester and a 1. INTRODUCTION conditions, as well as aWith controlled combine harvester and ita controlled field sample. reference to these restrictions, 1. INTRODUCTION conditions, as well as aWith controlled combine harvester and ita controlled field sample. reference to these restrictions, impossible tosample. carry out a large number of inspections on Combine harvester 1.isINTRODUCTION a large-scale complex agricultural is controlled field With reference to these restrictions, it impossible to harvesters, carry out a and largeonly number of inspections on Combine harvester is a large-scale complex agricultural is the ex-factory a small number of machinery, and its reliability directly affects the effective is impossible to carry out a large number of inspections on the ex-factory a small number of Combine harvester is a large-scale complex agricultural machinery, and of its agricultural reliability directly affects effective may be harvesters, taken. This and is anonly one-sidedness for China's implementation production. At the present, the samples the ex-factory a small number of samples may be harvesters, taken. This and is anonly one-sidedness for China's machinery, and of its agricultural reliability directly affects the effective implementation production. At present, the diverse agricultural environment and it is difficult to achieve. domestic and international harvesting machinery is samples may be taken. This is an one-sidedness for China's diverse agricultural environment and it is difficult to achieve. implementation of agricultural production. At present, the domestic and harvesting machinery is The China Academy of Agricultural Mechanization Science developing in theinternational direction of high efficiency, high power, agricultural and itMechanization is difficult to achieve. The China Academyenvironment of Agricultural Science domestic and international harvesting machinery is diverse developing in the direction of high efficiency, high power, Technology, China On-line Electrical Technology wide cuttingin width, and large feeding amount.high Thispower, trend and The China Academy of Agricultural Mechanization Science and Technology, China On-line Electrical Technology developing the direction of high efficiency, wide cutting and large feeding amount.process, This trend Co., Ltd. and related companies jointly developed requires morewidth, data support in the production and Equipment and Technology, China On-line Electrical Technology Equipment Co., Ltd. and related companies jointly developed wide cutting width, and large feeding amount. This trend requires more data support in the production produced a mobile agricultural safety asks performance testing system of the combine process, harvesterand for and Co., Ltd. and related companiesmachinery jointly developed and produced a mobile agricultural machinery safety requires more data support in the production asks performance testing system of the combine process, harvesterand for Equipment performance testing line. The inspection line mainly includes higher requirements. According to statistics, when the and produced a mobile agricultural machinery safety testing line. The inspection line mainly includes asks performance testingAccording system of the for performance higher requirements. to combine statistics,harvester when the such as brake and axle weight detection harvesting machinery works in the field, electrical system equipment performance testing line. The inspection line mainly includes such as detector, brake steering and axle weight higher requirements. According to statistics, when the equipment harvesting machinery works headlight wheel torque detection detector, fault accounts for about 30%inofthe thefield, total electrical faults, andsystem even equipment, equipment such as detector, brake steering and axle weight equipment, headlight wheel torque detection detector, harvesting machinery works inofthe field, electrical system fault accounts for about 30% the total faults, and even and hand brake force meter, smoke meter, and causes more fire accidents. Therefore, the harvester should pedal equipment, headlight detector, steering wheel torque pedal and hand brake force meter, smoke meter, and fault accounts foraccidents. about 30% of the total faults, andshould even electronic power consumption meter. The inspectiondetector, causes more fire the harvester line can comprehensively diagnose itsTherefore, electrical system before leaving pedal and hand brake force meter, smoke meter, and electronic power consumption meter. The inspection line can causes more fire accidents. Therefore, the harvester should comprehensively diagnosethe its harvester's electrical system before leaving data computer, data processing, digital display, data the factory and improve delivery, which can realize electronic power consumption meter. The inspection line can realize data computer, data processing, digital display, data comprehensively diagnose its electrical system before leaving the andaccident improverate. the harvester's delivery, which can saving and print test results. The field diagnostics and alsofactory reduce the realize data computer, data processing, digital display, data saving and print test results. The field diagnostics and the factory and improve the harvester's delivery, which can also reduce the accident rate. troubleshooting methods for the electrical of the small saving and print test results. The fieldfaults diagnostics and methods for the electrical faults of the small also reduce the accident Many research institutesrate. have conducted relevant research troubleshooting crawler rice combine harvester is introduced (Delin Ma, methods for the electrical faults of the small Many research institutes have conducted relevant research troubleshooting riceelectrical combine harvester introduced (Delin Ma, and achieved some results about the electrical system crawler 2015). The system of theisharvester was divided into Manyachieved research some institutes have about conducted relevant research and results the electrical system crawler rice combine harvester is introduced (Delin Ma, 2015). The electrical system of the harvester was divided into performance test system of harvesting machinery. For starter circuit, charging circuit, lighting circuit and control and achieved test some resultsof about the electrical system 2015). The electrical system of the harvester was divided into performance system harvesting machinery. For starter circuit, charging circuit, lighting circuit and control example, the “Combine Capacity and Performance Test Several typical causes of failure were analysed. These performance test system Capacity of harvesting machinery. Test For circuit. starter circuit, charging circuit, lightingwere circuit and control example, the “Combine and Performance circuit. Several typical causes of failure analysed. These Procedure” under the American ASABE standard is used to studies mainly focused on the detection of single parts or example, the “Combine Capacity and standard Performance Test circuit. Several typical causes of detection failure were These Procedure” under the cleaning American ASABE is used to focused on harvester, the of analysed. single parts or test the threshing the combine harvester. is studies workingmainly mechanisms of the and they only stayed at Procedure” under and the cleaning Americanof ASABE standard is usedIt to studies mainly focused on the detection of single parts or test the threshing and of the combine harvester. It is working mechanisms of the harvester, and they only stayed at required that there iscleaning a sample field that meets the actual the laboratory stage, failing to promote practical applications. test the threshing and of the combine harvester. It is mechanisms of the to harvester, they only stayed at required that there is a sample field that meets the actual working the laboratory stage, failing promoteand practical applications. required that there is a sample field that meets the actual the laboratory stage, failing to promote practical applications.
2405-8963 © 2018, IFAC (International Federation of Automatic Control) Hosting by Elsevier Ltd. All rights reserved. Copyright 2018 responsibility IFAC 363Control. Peer review©under of International Federation of Automatic Copyright © 2018 IFAC 363 10.1016/j.ifacol.2018.08.195 Copyright © 2018 IFAC 363
IFAC BIOROBOTICS 2018 364 Beijing, China, July 13-15, 2018
Dong Sun et al. / IFAC PapersOnLine 51-17 (2018) 363–367
This paper proposes the detection principle of the electrical system of the combine harvester and studies the detection method of electrical system operation reliability, which is of great value to improve the reliability of the electrical system performance test system of the combine harvester.
of the back electromotive voltage, the change of the motor rotation speed can be introduced. The motor rotation speed directly affects the performance of the motor. Therefore, using the starting current waveform to detect the starting motor is feasible.
2. THEORETICAL CONSIDERATION
3. MATERIAL AND METHOD
As the core component of the electrical system, the engine test is the most important part of electrical test stand. This paper proposes a detection method to detect the cylinder compression pressure state by detecting the engine start current waveform. The starting current of the engine is the inrush current when the starter motor has just started. It is the amount of current change during the short time from the start of the motor energization to the smooth operation.
3.1 Analyse of Combine Harvester Electrical System
During the engine start-up phase, the relationship between the torque M generated by the starter and the starting current is:
At present, the functional appliances of the combine harvester mainly include lights, width lamps, work lights, reversing lights, horns, air conditioners, wipers, radios, CAN meters, etc. For the same type of combine harvester, the rated operating power of its functional appliances should be basically consistent. During work process, in the case of voltage is basically unchanged, the rated operating current should be maintained within a fixed range. Based on this, the current method is used to quickly test the functional performance of the combined harvester functional electrical apparatus. In working process, the battery voltage remains basically the same, so the current method can be used to quickly determine whether a certain functional appliance can work normally, and to judge whether the functional appliance is qualified or not.
M= CmHI s where: M is the starting torque (N·m),
In order to meet the requirements of electrical system detection in the actual production process, the principles and methods applicable to the off-line detection of the electrical system of the combine harvester are put forward by analysing the working principle of the combine harvester, the structure of the components and the matching of the electrical system.
(1)
Cm is the motor
constant related to the motor structure, H is the magnetic flux (Wb);
I s is the starting current
In the starting motor, the armature rotates in the magnetic field, and the armature winding cuts the magnetic field lines of the magnetic field, thereby inducing a back electromotive force in the winding, and the relationship with the motor rotation speed is:
Es =CeHn where:
In order to detect the starter system quickly, this paper proposes a detection method based on current and voltage. The method mainly includes: using current sensor to measure the maximum and effective value of the current in the startup process, and get the start-up time, using the voltage regulation module to measure the maximum value and effective value of the voltage drop between the positive electrode of the battery and the positive electrode of the starter, the negative electrode of the battery and the ground during the start-up process, and obtain the charging voltage of the battery through the CAN bus. Then calculate the positive and negative battery main cable resistance. If the voltage drop value or resistance value is large, it indicates that there is a problem such as a cable fault in the system starter line.
(2)
Es is the back electromotive voltage, Ce is constant
related to motor structure,
Hn is motor rotation speed
The relationship between motor armature terminal voltage, armature internal resistance and armature current is:
I s=
U- Es Rs
where: U is motor armature terminal voltage,
(3)
Rs is armature
internal resistance The above formula is the voltage balance equation of the motor. Because the back electromotive voltage is opposite to the supply voltage and the armature resistance is small,
3.2 Electrical System Performance Test Stand Design Electrical system performance test stand consists of control cabinets, monitors and sensors. The control cabinet includes hardware such as computers, printers, electrical parameter testers, and data acquisition modules. It is the main part of electrical performance testing. The display provides operating information for the driver of the combine harvester and instructs the driver to operate in sequence. The sensor is used to detect electrical current and starting current for electrical
usually around 0.02 Ω , the magnitude of the back electromotive voltage has a great influence on the armature current. A small change in back electromotive voltage causes a large change in the armature current. The above part is the theoretical basis for the current detection method for starter motor. By detecting the starting current of the starting motor, we can push back the change of the back electromotive voltage. And according to the change 364
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performance testing and start-up performance evaluation. The overall structure of the test stand is as follows:
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analysis results of this test. Only after the password is correctly entered, the qualified interval of the detection parameters can be set. The function module mainly realizes the data reading and processing. The most important part of the data analysis is the reports generation. The report contains all the information of the detection, including the detection personnel information, machine number, qualified intervals of the parameters, actual values of the parameters, etc. It can be used as a qualified basis for the electrical system of the combine harvester. Data playback can display historical data through line charts and tables, which is convenient for observing the changing trend of parameters. The data display part displays the processed data through chart controls and numerical controls.
The test stand has mainly functions as follow: current detection, voltage detection, engine speed detection and CAN bus data analyse.
Enter personal information Test item selection
Fig. 1. Test stand structure diagram Electrical parameter test
The test stand is applied to the factory inspection of the combine harvester, so the rapidity of the detection is required to be high. So we use non-contact clamp-type current sensor ETCR 007AD to detect the functional device current and the ETCR 035AD to detect the starting current. In order to get CAN bus data, we use USB-CAN-2E-U module to analyse CAN bus data. And we use encoder to get engine rotation speed.
Startup parameter test
Parameter larger than threshold?
no
Warning and data saving
Combine harvester electrical system performance test software was designed based on the modularization idea. The software mainly consists of four parts: information input, function modules, data analysis, and data display. The main functions include entering the machine number and detecting personnel information; setting the qualified interval of the detection parameters; displaying the data collected by the sensor and displaying it on the virtual instrument of the software; realizing the storage and playback of the detected data and generating and printing the detection report.
CAN parameter test
Data processing Data playback
Report generation
Fig. 3. Flow chart of electrical system performance test software
Electrical system performance test software
Information input
Function module
Data alalyse
Data display
value
chart
Data playback
Report print
Data storage
CAN protocol analysw
Signal processing
Data acquisition
Qualified parameter interval
Harvester number
Person information
Fig. 2. Software functional diagram
Fig. 4. Main interface of test stand software
Fig.3. shows the flow chart of electrical performance test software according to the needs of the test stand and the hardware installation location.
Fig.4. shows the electrical current detection interface where area 1 is detection report area, area 2 is current curve area, a software control area, area 3 is information input area, area 4 is project selection area, area 5 is information prompt area, area 6 is detection operation area and area 7 is time display area.
The most important part of the information entry is the setting of the qualified interval of parameters. Since the parameter setting is very important, it will directly affect the 365
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From the chart above, it can be found that the alarm light of the combine harvester numbered YM1504948 has a weak current, and the interface of its alarm light is found to be falsely connected. No. YM1504949 combined harvester high beam and front and back operations and other currents are quite different from other machines in the same batch. After testing, it is found that the lighting system has wiring errors.
4. RESULTS AND DISCUSSION After completing the development of the hardware and software platform of the electrical system performance test stand, it is necessary to verify the operation flow of the test stand, the efficiency of the detection process, and the consistency and accuracy of the detection data. This article aims at the combine harvester as the test object. In July 2015, at the plant's assembly line of a certain type of harvester, the developed electrical system performance test stand was used to test the electrical performance of the complete machine in the following three aspects:
In the start current detection test, 8 sets of combine harvesters were randomly selected for testing. The test data are as follows: Table 1. Start current test results
(1) Functional electrical current detection test: During the functional electrical current detection process, the operator of the quality inspection personnel prompts the driver to open different electrical equipment, and a test stand performs rapid diagnosis of the status of all functional electrical appliances of a harvester. The system also save the test results as data and reports. (2) Start-up current detection test: Tests and verifications have been conducted on the data response characteristics of start-up current, the consistency of test data, and the correlation of voltage and current data.
Number
Start current (A)
Start time（ ms）
YM1504939 YM1504940 YM1504941 YM1504942 YM1504943 YM1504944 YM1504944 YM1504945
360.8 358.9 392.1 385.4 423.8 388.0 416.3 390.0
666.6 727.2 909.0 787.8 1030.2 909.0 545.4 545.4
Positive voltage drop value(V) 0.0 0.0 0.0 0.4 0.5 0.5 0.6 0.5
Negative voltage drop value(V) 0.5 0.5 0.5 0.5 0.7 0.6 0.7 0.7
It can be seen from the above table that the starting current and the positive and negative pressure drop variations are consistent. The harvesting machine with the number YM1504939 has a starting current of 360.8A and a negative pressure drop of 0.5V, while the harvester with the number YM1504943 has a starting current of 423.8A, the corresponding negative pressure drop is 0.7V. It is proved that during the start-up process, due to the large instantaneous current, there is a certain voltage drop between the positive and negative terminals of the battery. If the cable is in poor contact or the quality is poor, a greater voltage drop will be generated, affecting the start-up performance of the harvester. The change characteristics of the start-up current and positive and negative pressure drop of some tested harvesters are also different. The main reason is that after the assembly line is assembled, the engine has not been adjusted to the optimal operating state, the injection process is not stable, and the start-up characteristics are consistent.
Fig. 5. Electrical system performance online verification test stand 12 sets of combine harvesters were randomly selected for testing of the functional electrical currents. The results are as follows:
In the actual on-site inspection process, the detection time of a single combine harvester can be controlled within 5 minutes, fully meeting the actual production requirements. 5. CONCLUSIONS In this paper, according to the requirements of the off-line detection of the combined harvester electrical system, a method combining current and voltage detection is proposed to detect the electrical performance of the complete machine. The starting current curve evaluation method is used to detect the engine start-up parameters, and rapid online fault diagnosis is realized. Based on the modularization idea, the development of electrical performance test stand is completed. At the same time, based on the virtual instrument
Fig. 6. Functional electrical currents test results 366
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development platform, a test software integrating parameter setting, data acquisition, result analysis and data storage is developed. In order to verify the feasibility of the system, workshop verification tests were carried out on the combine harvester production line, and a comprehensive test was conducted on the static parameters and dynamic parameter detection flow of the electrical system of the complete machine. 6. ACKNOWLEDGEMENT This paper is financially supported by the Thirteen Fifth National Key Research and Development Program of China (Grant No. 2017YFD0700204) and Chinese Universities Scientific fund (2018GX001). REFERENCES Chiara Ciandrini, Marco Gallieri, Andrea Giantomassi, Gianluca Ippoliti and Sauro Longhi(2010). Fault detection and prognosis methods for a monitoring system of rotating electrical machines. IEEE, 2085-2090. Delin Ma(2015). Field Fault Diagnosis and Elimination of Electrical System of Small Crawler Rice Combine Harvester. Farm Machinery Guide, 48-49. Geert Craessaerts, Tom Coen, Josse DeBaerdemaeker(2005). Identification of sensor fau1ts on combine harvesters using intelligent methods. IFAC World congress. Jun Xu, Gangyan Li, Jian Hu and Taotao Chen(2012). Development of On-line Test System for Automobile Cab Electrical Appliances. Car Technology, 4, 20-24. Kevin Fitzgibbon, Larry Kirkland, Nicholas Flann,Nathan Wilson(2002). An electrical current flow technology for generation of automated testing equipment. IEEE, 845860. Li Dong, Yue Huang(2013). Correct diagnosis of tractor electrical circuit faults. Southern Agricultural Machinery, 6, 46. Malakondaiah Naidu, Thomas J, SchoepfSuresh Gopalakrishnan(2005). Arc fault detection schemes for an automotive 42V wire harness. SAE World Congress, 1. Yongbeom, Kim Yoongong, Kim Dohoon, Oh Wooseok, HanInwoo and Lee Kyounghoon(2018). Development of an automatic assembly machine for oyster farm lines. Journal of Institute of Control, Robotics and Systems, 24,111-115. Yap Kin, Sudhanshu Jamuar and Azmi Yahya(2011). Combine harvester instrumentation system for use in precision Agriculture. Instrumentation Science&Technology, 39, 374-393.
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ScienceDirect
IFAC PapersOnLine 51-17 (2018) 363–367
Development on electrical system performance test stand Development on electrical system performance test stand for combine harvester Development on electrical system performance test stand for combine harvester for combine harvester
Dong Sun*. Du Chen**. Shumao Wang***. Xin Wang**** Dong Sun*. Du Chen**. Shumao Wang***. Xin Wang**** Dong Sun*. Du Chen**. Shumao Wang***. Xin Wang**** *College of Engineering, China Agricultural University, Beijing 100083, China *College of Engineering, China Agricultural University, Beijing 100083, China (email: [email protected]) *College of Engineering, (email: China Agricultural University, Beijing 100083, China [email protected]) ** College of Engineering, China Agricultural University, Beijing 100083, China [email protected]) ** College of Engineering,(email: China Agricultural University, Beijing 100083, China (Corresponding author, Tel: 86-10-62736591; email: [email protected]) ** (Corresponding College of Engineering, China Agricultural University, Beijing 100083, China author, Tel: 86-10-62736591; email: [email protected]) *** Beijing Key Laboratory of Optimized Design for Modern Agricultural Equipment, Beijing 100083, China (Corresponding author, Tel: 86-10-62736591; email: [email protected]) *** Beijing Key Laboratory of Optimized Design for Modern Agricultural Equipment, Beijing 100083, China (email: [email protected]) *** Beijing Key Laboratory of Optimized Design for Modern Agricultural Equipment, Beijing 100083, China (email: [email protected]) **** College of Engineering, China Agricultural University, Beijing 100083, China (email: [email protected]) **** College of Engineering, China Agricultural University, Beijing 100083, China (email: [email protected]) **** College of Engineering, China Agricultural University, Beijing 100083, China (email: [email protected]) (email: [email protected]) Abstract: Combine harvester is a large-scale multi-functional agricultural equipment integrating Abstract: Combine harvester is a large-scale multi-functional agricultural equipment integrating functions of picking, conveying, threshing and separating, and its working mechanism and electrical Abstract: ofCombine a large-scale multi-functional equipment functions picking, harvester conveying,isthreshing and separating, and its agricultural working mechanism andintegrating electrical system are complicated. According to statistics, when the harvesting machinery works in the field, the functions picking, conveying, and when separating, and its working mechanism electrical system areofcomplicated. Accordingthreshing to statistics, the harvesting machinery works in and the field, the fault of the electrical system accounts for about 30%, and there are even fire accidents caused by system According to statistics, when theand harvesting machinery in thecaused field, the fault ofare thecomplicated. electrical system accounts for about 30%, there are even fireworks accidents by electrical failures. Therefore, the harvester should comprehensively diagnose its electrical system fault of the electrical system accounts for about 30%, and there are diagnose even fire its accidents caused by electrical failures. Therefore, the harvester should comprehensively electrical system performance before leaving the the factory to improve the quality of the combined harvester and reduce the electrical failures. harvester should diagnose its electrical system performance before Therefore, leaving the factory to improve the comprehensively quality of the combined harvester and reduce the accident rate. In this paper, according to the needs of the detection of the combine harvester production performance the factorytotothe improve quality of theofcombined harvester and production reduce the accident rate.before In thisleaving paper, according needs the of the detection the combine harvester off-line, electrical detection parameters are proposed and an overall plan for the electrical system accident rate. In this paper, according to the needs of the detection of the combine harvester production off-line, electrical detection parameters are proposed and an overall plan for the electrical system performance test stand is formulated. The current and voltage detection methods are used to detect the off-line, electrical detection parameters proposed and andetection overall plan for are the used electrical system performance test stand is formulated. Theare current and voltage methods to detect the electrical parameters of the whole machine. The starting current curve evaluation method is used to performance test standofisthe formulated. The current voltage detection aremethod used to isdetect electrical parameters whole machine. The and starting current curve methods evaluation used the to detect the engine startup parameters. In order to verify the feasibility of the test stand, on-site verification electrical of parameters. the whole machine. starting current curve is used to detect the parameters engine startup In order toThe verify the feasibility of theevaluation test stand, method on-site verification tests were carried out on the combine harvester production line, and a comprehensive test was conducted detectwere the engine order to production verify the feasibility the test stand, test on-site tests carriedstartup out on parameters. the combineInharvester line, and aofcomprehensive wasverification conducted on the detection efficiency, static parameters, and dynamic parameter detection flow of the whole tests were carried out on the combine harvester production line, parameter and a comprehensive test was conducted on the detection efficiency, static parameters, and dynamic detection flow of the whole electrical system. Off-line tests showparameters, that the test stand can meet the rapid detection requirements of the on the detection efficiency, dynamic parameter flow of the whole electrical system. Off-line testsstatic show that the testand stand can meet the rapid detection detection requirements of the electrical system of the combined harvester production line, improve the detection efficiency. electrical system system.ofOff-line tests show that the test standline, can improve meet thethe rapid detection requirements of the the combined harvester production detection efficiency. electrical system of the combined harvester production line, improve the detection efficiency. © 2018, IFAC (International Federation of system; Automatic Control) Hosting virtual by Elsevier Ltd. Alloff-line rights reserved. Keywords: combine harvester; electrical quality inspection; instrument; detection; Keywords: combine harvester; electrical system; quality inspection; virtual instrument; off-line detection; Keywords: combine harvester; electrical system; quality inspection; virtual instrument; off-line detection; conditions, as well as a controlled combine harvester and a 1. INTRODUCTION conditions, as well as aWith controlled combine harvester and ita controlled field sample. reference to these restrictions, 1. INTRODUCTION conditions, as well as aWith controlled combine harvester and ita controlled field sample. reference to these restrictions, impossible tosample. carry out a large number of inspections on Combine harvester 1.isINTRODUCTION a large-scale complex agricultural is controlled field With reference to these restrictions, it impossible to harvesters, carry out a and largeonly number of inspections on Combine harvester is a large-scale complex agricultural is the ex-factory a small number of machinery, and its reliability directly affects the effective is impossible to carry out a large number of inspections on the ex-factory a small number of Combine harvester is a large-scale complex agricultural machinery, and of its agricultural reliability directly affects effective may be harvesters, taken. This and is anonly one-sidedness for China's implementation production. At the present, the samples the ex-factory a small number of samples may be harvesters, taken. This and is anonly one-sidedness for China's machinery, and of its agricultural reliability directly affects the effective implementation production. At present, the diverse agricultural environment and it is difficult to achieve. domestic and international harvesting machinery is samples may be taken. This is an one-sidedness for China's diverse agricultural environment and it is difficult to achieve. implementation of agricultural production. At present, the domestic and harvesting machinery is The China Academy of Agricultural Mechanization Science developing in theinternational direction of high efficiency, high power, agricultural and itMechanization is difficult to achieve. The China Academyenvironment of Agricultural Science domestic and international harvesting machinery is diverse developing in the direction of high efficiency, high power, Technology, China On-line Electrical Technology wide cuttingin width, and large feeding amount.high Thispower, trend and The China Academy of Agricultural Mechanization Science and Technology, China On-line Electrical Technology developing the direction of high efficiency, wide cutting and large feeding amount.process, This trend Co., Ltd. and related companies jointly developed requires morewidth, data support in the production and Equipment and Technology, China On-line Electrical Technology Equipment Co., Ltd. and related companies jointly developed wide cutting width, and large feeding amount. This trend requires more data support in the production produced a mobile agricultural safety asks performance testing system of the combine process, harvesterand for and Co., Ltd. and related companiesmachinery jointly developed and produced a mobile agricultural machinery safety requires more data support in the production asks performance testing system of the combine process, harvesterand for Equipment performance testing line. The inspection line mainly includes higher requirements. According to statistics, when the and produced a mobile agricultural machinery safety testing line. The inspection line mainly includes asks performance testingAccording system of the for performance higher requirements. to combine statistics,harvester when the such as brake and axle weight detection harvesting machinery works in the field, electrical system equipment performance testing line. The inspection line mainly includes such as detector, brake steering and axle weight higher requirements. According to statistics, when the equipment harvesting machinery works headlight wheel torque detection detector, fault accounts for about 30%inofthe thefield, total electrical faults, andsystem even equipment, equipment such as detector, brake steering and axle weight equipment, headlight wheel torque detection detector, harvesting machinery works inofthe field, electrical system fault accounts for about 30% the total faults, and even and hand brake force meter, smoke meter, and causes more fire accidents. Therefore, the harvester should pedal equipment, headlight detector, steering wheel torque pedal and hand brake force meter, smoke meter, and fault accounts foraccidents. about 30% of the total faults, andshould even electronic power consumption meter. The inspectiondetector, causes more fire the harvester line can comprehensively diagnose itsTherefore, electrical system before leaving pedal and hand brake force meter, smoke meter, and electronic power consumption meter. The inspection line can causes more fire accidents. Therefore, the harvester should comprehensively diagnosethe its harvester's electrical system before leaving data computer, data processing, digital display, data the factory and improve delivery, which can realize electronic power consumption meter. The inspection line can realize data computer, data processing, digital display, data comprehensively diagnose its electrical system before leaving the andaccident improverate. the harvester's delivery, which can saving and print test results. The field diagnostics and alsofactory reduce the realize data computer, data processing, digital display, data saving and print test results. The field diagnostics and the factory and improve the harvester's delivery, which can also reduce the accident rate. troubleshooting methods for the electrical of the small saving and print test results. The fieldfaults diagnostics and methods for the electrical faults of the small also reduce the accident Many research institutesrate. have conducted relevant research troubleshooting crawler rice combine harvester is introduced (Delin Ma, methods for the electrical faults of the small Many research institutes have conducted relevant research troubleshooting riceelectrical combine harvester introduced (Delin Ma, and achieved some results about the electrical system crawler 2015). The system of theisharvester was divided into Manyachieved research some institutes have about conducted relevant research and results the electrical system crawler rice combine harvester is introduced (Delin Ma, 2015). The electrical system of the harvester was divided into performance test system of harvesting machinery. For starter circuit, charging circuit, lighting circuit and control and achieved test some resultsof about the electrical system 2015). The electrical system of the harvester was divided into performance system harvesting machinery. For starter circuit, charging circuit, lighting circuit and control example, the “Combine Capacity and Performance Test Several typical causes of failure were analysed. These performance test system Capacity of harvesting machinery. Test For circuit. starter circuit, charging circuit, lightingwere circuit and control example, the “Combine and Performance circuit. Several typical causes of failure analysed. These Procedure” under the American ASABE standard is used to studies mainly focused on the detection of single parts or example, the “Combine Capacity and standard Performance Test circuit. Several typical causes of detection failure were These Procedure” under the cleaning American ASABE is used to focused on harvester, the of analysed. single parts or test the threshing the combine harvester. is studies workingmainly mechanisms of the and they only stayed at Procedure” under and the cleaning Americanof ASABE standard is usedIt to studies mainly focused on the detection of single parts or test the threshing and of the combine harvester. It is working mechanisms of the harvester, and they only stayed at required that there iscleaning a sample field that meets the actual the laboratory stage, failing to promote practical applications. test the threshing and of the combine harvester. It is mechanisms of the to harvester, they only stayed at required that there is a sample field that meets the actual working the laboratory stage, failing promoteand practical applications. required that there is a sample field that meets the actual the laboratory stage, failing to promote practical applications.
2405-8963 © 2018, IFAC (International Federation of Automatic Control) Hosting by Elsevier Ltd. All rights reserved. Copyright 2018 responsibility IFAC 363Control. Peer review©under of International Federation of Automatic Copyright © 2018 IFAC 363 10.1016/j.ifacol.2018.08.195 Copyright © 2018 IFAC 363
IFAC BIOROBOTICS 2018 364 Beijing, China, July 13-15, 2018
Dong Sun et al. / IFAC PapersOnLine 51-17 (2018) 363–367
This paper proposes the detection principle of the electrical system of the combine harvester and studies the detection method of electrical system operation reliability, which is of great value to improve the reliability of the electrical system performance test system of the combine harvester.
of the back electromotive voltage, the change of the motor rotation speed can be introduced. The motor rotation speed directly affects the performance of the motor. Therefore, using the starting current waveform to detect the starting motor is feasible.
2. THEORETICAL CONSIDERATION
3. MATERIAL AND METHOD
As the core component of the electrical system, the engine test is the most important part of electrical test stand. This paper proposes a detection method to detect the cylinder compression pressure state by detecting the engine start current waveform. The starting current of the engine is the inrush current when the starter motor has just started. It is the amount of current change during the short time from the start of the motor energization to the smooth operation.
3.1 Analyse of Combine Harvester Electrical System
During the engine start-up phase, the relationship between the torque M generated by the starter and the starting current is:
At present, the functional appliances of the combine harvester mainly include lights, width lamps, work lights, reversing lights, horns, air conditioners, wipers, radios, CAN meters, etc. For the same type of combine harvester, the rated operating power of its functional appliances should be basically consistent. During work process, in the case of voltage is basically unchanged, the rated operating current should be maintained within a fixed range. Based on this, the current method is used to quickly test the functional performance of the combined harvester functional electrical apparatus. In working process, the battery voltage remains basically the same, so the current method can be used to quickly determine whether a certain functional appliance can work normally, and to judge whether the functional appliance is qualified or not.
M= CmHI s where: M is the starting torque (N·m),
In order to meet the requirements of electrical system detection in the actual production process, the principles and methods applicable to the off-line detection of the electrical system of the combine harvester are put forward by analysing the working principle of the combine harvester, the structure of the components and the matching of the electrical system.
(1)
Cm is the motor
constant related to the motor structure, H is the magnetic flux (Wb);
I s is the starting current
In the starting motor, the armature rotates in the magnetic field, and the armature winding cuts the magnetic field lines of the magnetic field, thereby inducing a back electromotive force in the winding, and the relationship with the motor rotation speed is:
Es =CeHn where:
In order to detect the starter system quickly, this paper proposes a detection method based on current and voltage. The method mainly includes: using current sensor to measure the maximum and effective value of the current in the startup process, and get the start-up time, using the voltage regulation module to measure the maximum value and effective value of the voltage drop between the positive electrode of the battery and the positive electrode of the starter, the negative electrode of the battery and the ground during the start-up process, and obtain the charging voltage of the battery through the CAN bus. Then calculate the positive and negative battery main cable resistance. If the voltage drop value or resistance value is large, it indicates that there is a problem such as a cable fault in the system starter line.
(2)
Es is the back electromotive voltage, Ce is constant
related to motor structure,
Hn is motor rotation speed
The relationship between motor armature terminal voltage, armature internal resistance and armature current is:
I s=
U- Es Rs
where: U is motor armature terminal voltage,
(3)
Rs is armature
internal resistance The above formula is the voltage balance equation of the motor. Because the back electromotive voltage is opposite to the supply voltage and the armature resistance is small,
3.2 Electrical System Performance Test Stand Design Electrical system performance test stand consists of control cabinets, monitors and sensors. The control cabinet includes hardware such as computers, printers, electrical parameter testers, and data acquisition modules. It is the main part of electrical performance testing. The display provides operating information for the driver of the combine harvester and instructs the driver to operate in sequence. The sensor is used to detect electrical current and starting current for electrical
usually around 0.02 Ω , the magnitude of the back electromotive voltage has a great influence on the armature current. A small change in back electromotive voltage causes a large change in the armature current. The above part is the theoretical basis for the current detection method for starter motor. By detecting the starting current of the starting motor, we can push back the change of the back electromotive voltage. And according to the change 364
IFAC BIOROBOTICS 2018 Beijing, China, July 13-15, 2018
Dong Sun et al. / IFAC PapersOnLine 51-17 (2018) 363–367
performance testing and start-up performance evaluation. The overall structure of the test stand is as follows:
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analysis results of this test. Only after the password is correctly entered, the qualified interval of the detection parameters can be set. The function module mainly realizes the data reading and processing. The most important part of the data analysis is the reports generation. The report contains all the information of the detection, including the detection personnel information, machine number, qualified intervals of the parameters, actual values of the parameters, etc. It can be used as a qualified basis for the electrical system of the combine harvester. Data playback can display historical data through line charts and tables, which is convenient for observing the changing trend of parameters. The data display part displays the processed data through chart controls and numerical controls.
The test stand has mainly functions as follow: current detection, voltage detection, engine speed detection and CAN bus data analyse.
Enter personal information Test item selection
Fig. 1. Test stand structure diagram Electrical parameter test
The test stand is applied to the factory inspection of the combine harvester, so the rapidity of the detection is required to be high. So we use non-contact clamp-type current sensor ETCR 007AD to detect the functional device current and the ETCR 035AD to detect the starting current. In order to get CAN bus data, we use USB-CAN-2E-U module to analyse CAN bus data. And we use encoder to get engine rotation speed.
Startup parameter test
Parameter larger than threshold?
no
Warning and data saving
Combine harvester electrical system performance test software was designed based on the modularization idea. The software mainly consists of four parts: information input, function modules, data analysis, and data display. The main functions include entering the machine number and detecting personnel information; setting the qualified interval of the detection parameters; displaying the data collected by the sensor and displaying it on the virtual instrument of the software; realizing the storage and playback of the detected data and generating and printing the detection report.
CAN parameter test
Data processing Data playback
Report generation
Fig. 3. Flow chart of electrical system performance test software
Electrical system performance test software
Information input
Function module
Data alalyse
Data display
value
chart
Data playback
Report print
Data storage
CAN protocol analysw
Signal processing
Data acquisition
Qualified parameter interval
Harvester number
Person information
Fig. 2. Software functional diagram
Fig. 4. Main interface of test stand software
Fig.3. shows the flow chart of electrical performance test software according to the needs of the test stand and the hardware installation location.
Fig.4. shows the electrical current detection interface where area 1 is detection report area, area 2 is current curve area, a software control area, area 3 is information input area, area 4 is project selection area, area 5 is information prompt area, area 6 is detection operation area and area 7 is time display area.
The most important part of the information entry is the setting of the qualified interval of parameters. Since the parameter setting is very important, it will directly affect the 365
IFAC BIOROBOTICS 2018 366 Beijing, China, July 13-15, 2018
Dong Sun et al. / IFAC PapersOnLine 51-17 (2018) 363–367
From the chart above, it can be found that the alarm light of the combine harvester numbered YM1504948 has a weak current, and the interface of its alarm light is found to be falsely connected. No. YM1504949 combined harvester high beam and front and back operations and other currents are quite different from other machines in the same batch. After testing, it is found that the lighting system has wiring errors.
4. RESULTS AND DISCUSSION After completing the development of the hardware and software platform of the electrical system performance test stand, it is necessary to verify the operation flow of the test stand, the efficiency of the detection process, and the consistency and accuracy of the detection data. This article aims at the combine harvester as the test object. In July 2015, at the plant's assembly line of a certain type of harvester, the developed electrical system performance test stand was used to test the electrical performance of the complete machine in the following three aspects:
In the start current detection test, 8 sets of combine harvesters were randomly selected for testing. The test data are as follows: Table 1. Start current test results
(1) Functional electrical current detection test: During the functional electrical current detection process, the operator of the quality inspection personnel prompts the driver to open different electrical equipment, and a test stand performs rapid diagnosis of the status of all functional electrical appliances of a harvester. The system also save the test results as data and reports. (2) Start-up current detection test: Tests and verifications have been conducted on the data response characteristics of start-up current, the consistency of test data, and the correlation of voltage and current data.
Number
Start current (A)
Start time（ ms）
YM1504939 YM1504940 YM1504941 YM1504942 YM1504943 YM1504944 YM1504944 YM1504945
360.8 358.9 392.1 385.4 423.8 388.0 416.3 390.0
666.6 727.2 909.0 787.8 1030.2 909.0 545.4 545.4
Positive voltage drop value(V) 0.0 0.0 0.0 0.4 0.5 0.5 0.6 0.5
Negative voltage drop value(V) 0.5 0.5 0.5 0.5 0.7 0.6 0.7 0.7
It can be seen from the above table that the starting current and the positive and negative pressure drop variations are consistent. The harvesting machine with the number YM1504939 has a starting current of 360.8A and a negative pressure drop of 0.5V, while the harvester with the number YM1504943 has a starting current of 423.8A, the corresponding negative pressure drop is 0.7V. It is proved that during the start-up process, due to the large instantaneous current, there is a certain voltage drop between the positive and negative terminals of the battery. If the cable is in poor contact or the quality is poor, a greater voltage drop will be generated, affecting the start-up performance of the harvester. The change characteristics of the start-up current and positive and negative pressure drop of some tested harvesters are also different. The main reason is that after the assembly line is assembled, the engine has not been adjusted to the optimal operating state, the injection process is not stable, and the start-up characteristics are consistent.
Fig. 5. Electrical system performance online verification test stand 12 sets of combine harvesters were randomly selected for testing of the functional electrical currents. The results are as follows:
In the actual on-site inspection process, the detection time of a single combine harvester can be controlled within 5 minutes, fully meeting the actual production requirements. 5. CONCLUSIONS In this paper, according to the requirements of the off-line detection of the combined harvester electrical system, a method combining current and voltage detection is proposed to detect the electrical performance of the complete machine. The starting current curve evaluation method is used to detect the engine start-up parameters, and rapid online fault diagnosis is realized. Based on the modularization idea, the development of electrical performance test stand is completed. At the same time, based on the virtual instrument
Fig. 6. Functional electrical currents test results 366
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Dong Sun et al. / IFAC PapersOnLine 51-17 (2018) 363–367
development platform, a test software integrating parameter setting, data acquisition, result analysis and data storage is developed. In order to verify the feasibility of the system, workshop verification tests were carried out on the combine harvester production line, and a comprehensive test was conducted on the static parameters and dynamic parameter detection flow of the electrical system of the complete machine. 6. ACKNOWLEDGEMENT This paper is financially supported by the Thirteen Fifth National Key Research and Development Program of China (Grant No. 2017YFD0700204) and Chinese Universities Scientific fund (2018GX001). REFERENCES Chiara Ciandrini, Marco Gallieri, Andrea Giantomassi, Gianluca Ippoliti and Sauro Longhi(2010). Fault detection and prognosis methods for a monitoring system of rotating electrical machines. IEEE, 2085-2090. Delin Ma(2015). Field Fault Diagnosis and Elimination of Electrical System of Small Crawler Rice Combine Harvester. Farm Machinery Guide, 48-49. Geert Craessaerts, Tom Coen, Josse DeBaerdemaeker(2005). Identification of sensor fau1ts on combine harvesters using intelligent methods. IFAC World congress. Jun Xu, Gangyan Li, Jian Hu and Taotao Chen(2012). Development of On-line Test System for Automobile Cab Electrical Appliances. Car Technology, 4, 20-24. Kevin Fitzgibbon, Larry Kirkland, Nicholas Flann,Nathan Wilson(2002). An electrical current flow technology for generation of automated testing equipment. IEEE, 845860. Li Dong, Yue Huang(2013). Correct diagnosis of tractor electrical circuit faults. Southern Agricultural Machinery, 6, 46. Malakondaiah Naidu, Thomas J, SchoepfSuresh Gopalakrishnan(2005). Arc fault detection schemes for an automotive 42V wire harness. SAE World Congress, 1. Yongbeom, Kim Yoongong, Kim Dohoon, Oh Wooseok, HanInwoo and Lee Kyounghoon(2018). Development of an automatic assembly machine for oyster farm lines. Journal of Institute of Control, Robotics and Systems, 24,111-115. Yap Kin, Sudhanshu Jamuar and Azmi Yahya(2011). Combine harvester instrumentation system for use in precision Agriculture. Instrumentation Science&Technology, 39, 374-393.
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