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NUMERICAL CALCULUS OF THE MAXIMUM DISPLACEMENT BETWEEN

THE REEL’S AXES AND THE CUTTER BAR FROM COMBINE HARVESTERS

EDMOND MAICAN, VICTOR MOISE, SORIN-ŞTEFAN BIRIŞ


„Politehnica” University of Bucharest, Faculty of Biotechnical Systems Engineering
Splaiul Independentei, no.313, 060032, Bucharest, Romania

Summary. The first phase of the precision agriculture implementation is the numerical
modeling of the involved agricultural processes. These mathematical algorithms represent
the basis for the subsequent development of computer programs, written for
microprocessors controlling the modern agricultural machines’ working processes. This
paper solves analytically one of many adjustment and design problems from combine
harvesters’ reels: the maximum displacement of the reel’s axes in front of the cutter bar.
Until now, a method used to identify a solution for this problem was a graphical one, which
is inadequate for the above mentioned purpose. The system of two complex equations
found in this study is numerically solved by means of the Newton-Raphson method, which
has the advantage of a smaller number of iterations in comparison with other iterative
methods.
Key words: reel, cutter bar, numerical method, Newton-Raphson, cereal harvester.

1. INTRODUCTION
The good operation of a cereal harvester is very much influenced by its subassemblies’
adjustments which, until recently, where dependent on de skills of the operator.
Nevertheless, the human factor has its limitations, so the development of automation
systems was very much to the point. However, mathematical algorithms that control the
operation of these systems have to be developed first.
The first agricultural combine’s operating part that comes into contact with plants is
the reel. Its basic adjustments are related to the physical properties of the crop: height of
plants, minimum impact speed that induces seeds detachment from ears, field density, mean
position of the plants’ centre of gravity, degree of plants’ leaning in case of unfavourable
atmospheric conditions etc.
This paper solves one of many adjustment and design problems from combine
harvesters’ reels: the maximum displacement between the reel’s axes and the cutter bar. As
a first step, the algorithm that leads to the system of equations that solves the problem is
presented. These equations are complex and hard to solve analytically so, in the second
step, a computer program that makes use of the Newton-Raphson numerical method is
written in Pascal language. Of course, the system can also be solved in specific programs
like MathCAD, but these are improper for computers used in automation systems.

2. ANALYTICAL DETERMINATION OF THE REEL’S AXES


MAXIMUM DISPLACEMENT IN FRONT OF THE CUTTER BAR

In this chapter, the mathematical way that leads to the equation used to calculate the
maximum displacement of the reel’s axes in front of the cutter bar is presented. In order to
start the analytic proof, an initial condition must be established: the last plant from the
plants bundle pushed by one blade of the reel must be cut right before the moment when it
escapes from the blade’s action [1]. Figure 1 presents this last plant in two stages: first,
when it enters under the action of the reel (mA1), and then right in the moment when it has
to escape from the reel’s action (mA3). In this last moment the plant must come in contact
with the cutter bar (point C). Points A1, A2 and A3 belong to a cycloid which is the trajectory
of one reel’s peripheral point of the blade.
On the same figure, points O1 and O2 are the reel’s centres corresponding respectively
to the two moments mentioned above. Other notations from the figure are presented below:
R – radius of the reel;
l – length of the plant;
bmax – maximum displacement of the reel’s axes in front of the cutter bar;
h – distance between the cutter bar and soil;
H – vertical distance between the cutter bar and the axes of the reel;
vm – forward speed of the cereal harvester.
Different angles and a fixed coordinate system are also represented.

Fig. 1. Meaning of the notations used in the analytical proof

Analysing the figure above, it is obvious that the distance bmax can be calculated using
the following relation:
bmax  O1O3  ( R  cos 1  h  tg 3 ) (1)
If t1 and t3 are the time moments when the reel’s centre reaches points O1 respectively
O3, then the distance O1O3 can be evaluated with relation (2):
O1O3  vm (t3  t1 ) (2)
One of the most important parameters used in calculus of rotary working parts of
agricultural machinery is the kinematical index λ. In case of combine harvesters’ reels its
values must stay in the interval [1.15; 1.85] in order for the reel to lean the plants towards
the cutter bar. For values greater than 1.85, the higher peripheral speed of the reel means a
higher danger of seeds losses at impact. The kinematical index is calculated as:
R
 , where ω is the angular velocity of the reel.
vm
So, relation (2) can be written as:
R
O1O3  (t3  t1 )

R
 O1O3  (t3  t1 )

R
 O1O3  ( 3  1 ) (3)

Another component from equation (1) that must be determined is R  cos 1 :
R  cos 1  R 1  sin 2 1 (4)
As the reel’s blade must not induce seeds detachment from the ears, the horizontal
component vx of the blade when it first touches the plants (point A1) must be zero:
v x  0  vm  R sin 1  0
v
 sin 1  m
R
1
 sin 1  (5)

Going with relation (5) in (4):
R
R  cos 1  2  1 (6)

Also, if equations (4) and (6) are now inserted into (1), bmax becomes:
R R 2 
bmax  (3  1 )     1  h  tg 3  , or
   
bmax
R
 
  3  1  2  1  h  tg 3

(7)

If the coordinates of A1 and A3 are (x1, y1), respectively (x3, y3), than (see fig.1):
y32  ( x1  x3 ) 2  l 2 (8)
The A1 point’s abscissa (x1) is:
x1  vm  t1  R  cos1
However:
R R
v m  t1  t1  1 (9)
 
From equations (9) and (6) results:
R R
x1  1  2  1 , or
 
x1 
R

  1 2  1 
The angle φ1 can be evaluated from relation (5):
1
1  arcsin  (10)

So, abscissa x1 becomes:
R 1 
x1   arcsin    2  1  (11)
   
The A3 point’s abscissa (x3) is:
x3  vm  t3  R  cos 3 (12)
But:
R R
vm  t 3  t3  3
 
Equation (12) now becomes:
R
x3  3  R  cos 3 (13)

The y3 coordinate of point A3 can be calculated as follows (see fig.1):
y3  H  h  R  sin  3 (14)
Analyzing figure 1, one can notice that H  h  l  R  sin 1 . Considering relation (5):
R
H hl (15)

Therefore, equation (14) can be written as:
R
y3  l   R  sin  3 (16)

Parameters x1, x3 and y3 are now replaced in equation (8) according to relations (11),
(13), respectively (16) and results:
2
 R   R 
2
 R 1
 l   R  sin  3     arcsin      1     3  R  cos  3   l (17)
2 2

        
This equation will be the first out of two, to be used later in the system. Paying
attention to figure 1, it is observable that:
x1  x3
tg 3  (18)
y3
If x1, x3 and y3 are replaced according to equations (11), (13) and respectively (16),
relation (18) becomes:
R 1  R
 arcsin    2  1     3  R  cos  3
   
tg 3  
R
l   R  sin  3

After a few simple transformations, the above formula becomes:
1
arcsin    2  1   3    cos  3
tg 3  R 
(19)
l 
   sin  3   1
R 
Now, the system of two equations can be composed from (17) and (19):
 R  R 
2
1  R 
2

 l   R  sin  3     arcsin      1     3  R  cos  3   l 2


2

         

 arcsin  1   2  1   3    cos  3
   tg 3  0
R l 
    sin  3   1
 R 
This system will be solved by means of numerical methods, using Newton-Raphson
method. The unknowns are φ3 and tg(θ3) and their calculated values will be then used to
find the maximum displacement between the reel’s axes and the cutter bar bmax, as follows:
R 1 
bmax    3  arcsin    2  1   h  R (20)
   
The above formula is based on equations (7) and (10).

3. COMPUTER PROGRAM FOR NUMERICAL CALCULUS OF THE DISTANCE


BETWEEN THE REEL’S AXES AND THE CUTTER BAR

The intricate system of two equations presented above can be solved by means of
iterative numerical approach. There are two mostly used numerical approaches: Gradient
method and Newton-Raphson method. The equations should be first transformed into
functions. Initial guesses for each root are required by each method.
Both methods employ the partial derivatives of each function, so four partial
derivatives are necessary in this case. The Gradient method is always convergent, however
with a very slow rate of convergence. On the other hand, the Newton-Raphson method lead
to significant faster convergence, but it also allows the possibility that the solution may
diverge. It is well known that divergence can occur if the initial guesses are insufficiently
close to the true roots [2,3]. It is not the case with the problem presented in this paper, as
the initial guesses can be efficiently predicted by means of a simple scaled drawing of
figure 1.
Values for the following parameters must be defined in the program:
- R (which is distinctive for each model of cereal harvester);
- height of plants l (which, in the real case, can be permanently measured by means
of modern data acquisition systems, for example based on laser beam and
photoelectric cells);
- kinematical index λ (modern combine harvesters have automatic systems that
calculate and maintain the kinematical index between 1.15 and 1.85);
- distance between the cutter bar and soil h (which also can be easily automatically
determined in real case and stays approximately constant during the entire
harvesting process).
The program is presented below with test values for the above mentioned parameters,
according to the real situations that can be found in the field.

PROGRAM Maximum_displacement;
USES CRT,METODNUM;
{$M 65520,0,655360}
VAR X:VECTOR1; {Array with 200 elements, Unit Metodnum}
b_max,Lbd,L,hc,H,EPS,EPS2:REAL;
{------------------------------------------
b_max- maximum displacement
Lbd - lambda
L - height of plants
hc - distance between soil and cutter bar
------------------------------------------}
I,N,KOD,ITER:INTEGER;
CONST R:Real=0.5; {Radius of the reel}
{$F+}

PROCEDURE FUNCT(N:INTEGER;X:VECTOR1;VAR F:VECTOR1;VAR KOD:INTEGER);


BEGIN
KOD:=0;
F[1]:=sqr(L+R/Lbd-R*sin(x[1]))+sqr(R/Lbd*(arcsin(1/Lbd)+
sqrt(Lbd*Lbd-1))-(R/Lbd*x[1]+R*cos(x[1])))-L*L;
F[2]:=R*(arcsin(1/Lbd)-x[2]+sqrt(Lbd*Lbd-1)
+Lbd*cos(x[1]))/(Lbd*(L/R-sin(x[1]))+1)-x[2];
END;
{$F-}

PROCEDURE NewtRaphs(NUME:PROC6;MF:PROC7;N,ITER:INTEGER;
H,EPS:REAL;VAR X:VECTOR1;VAR KOD:INTEGER);
VAR I,J,JESF,N1:INTEGER; W,W1,DX,F:VECTOR1;
BEGIN
KOD:=0; N1:=N+1; I:=1;
REPEAT
MF(NUME,X,N,H,F,W,KOD);
INVMAT(W,N,1.E-15,W1,KOD);
IF KOD > 0 THEN
BEGIN
WRITELN(' KOD= ',KOD);
READLN;
EXIT;
END
ELSE
PRODMAT(W1,F,N,N,1,DX);
JESF:=0;
J:=1;
REPEAT
IF ABS(DX[J]) < EPS THEN
J:=J+1
ELSE BEGIN
J:=N1;
JESF:=1;
END;
UNTIL J > N;
IF JESF = 0 THEN EXIT;
FOR J:=1 TO N DO
X[J]:=X[J]-DX[J];
WRITELN(' ITERATION ',I);
FOR J:=1 TO N DO WRITELN('X[',J,']= ',X[J]);
I:=I+1;
UNTIL I > ITER;
WRITELN(' ERROR! '); EXIT;
END;
{________________Main Program_________________}
BEGIN
CLRSCR;
Lbd:=1.5;
L:=0.6 {m};
hc:=0.15 {m};
N:=2; {number of equations}
H:=0.015;
EPS:=1.E-5;{precision of calculus}
ITER:=30;{maximum number of iterations}
{---------------------}
{Initial guesses}
X[1]:=2.1; {fi3}
X[2]:=0.36;{tan(teta3)}
{---------------------}
NewtRaphs(FUNCT,MF,N,ITER,H,EPS,X,KOD);
WRITELN(^J^M,' ROOTS OF THE SYSTEM:');
FOR I:=1 TO N DO WRITELN(' X[',I,']= ',X[I]:10:4);
b_max:=R/Lbd*(x[1]-arcsin(1/Lbd)-sqrt(Lbd*Lbd-1))+hc*x[2];
Writeln(^J^M,' b_max=',b_max*100:6:1,' cm'); Readln;
END.

In this program, the Metodnum unit is a library of useful mathematical functions and
procedures made by authors [4]. NewtRaphs procedure calls on INVMAT and PRODMAT
procedures, which are used for calculating the inverse matrix and product of two matrixes
respectively. Also, the partial derivatives are solved numerically instead of analytical, by
means of the MF procedure. All three of them are defined in the Metodnum unit. The
Arcsin function is also defined by the authors [5] and included in the Metodnum unit,
together with other trigonometric functions.
In the definition line of NewtRaphs procedure, PROC6 and PROC7 are procedure type
parameters, defined in the Metodnum unit as follows:

PROC6=PROCEDURE(N:INTEGER;X:VECTOR1;VAR F:VECTOR1;VAR KOD:INTEGER);


PROC7=PROCEDURE(PROC:PROC6;X:VECTOR1;N:INTEGER;EPS:REAL;
VAR F,W:VECTOR1;VAR KOD:INTEGER);

The following input values were used in the program in order to test it: R = 0.5 m, l =
0.6 m, h = 0.15 m and λ = 1.5. Two initial guess values were given for φ3 and tg(θ3)
(denoted respectively with x[1] and x[2] in the program): φ3 = 2.1 rad (about 1200) and
tg(θ3) = 0.57 (for an initial value of θ3 of π/6). After the computation, the following results
were obtained:

ITERATION 1
X[1]= 2.3790941945E+00
X[2]= 1.5623981256E-01
ITERATION 2
X[1]= 2.3331766857E+00
X[2]= 1.8282658848E-01
ITERATION 3
X[1]= 2.3317922635E+00
X[2]= 1.8368969665E-01

ROOTS OF THE SYSTEM:


X[1]= 2.3318
X[2]= 0.1837

b_max= 18.9 cm

CONCLUSIONS

For the above input values, the maximum calculated displacement between the reel’s
axes and the cutter bar is bmax ≈ 19 cm. The second root (X[2]) shows that the plant is
inclined by the reel with an angle θ3 = 0.1817 rad (or 10.40). First root (X[1]) denotes the
angle φ3, which has a value of 2.33 rad (or 133.6 0).
One important aspect of this program is the small number of iterations. It translates
into a fast run, which is very helpful for the machine’s computer, whose role is to make a
large number of different kinds of calculations each second.

REFERENCES

[1]. Maican, E., Cercetări privind optimizarea procesului de lucru al rabatorului


combinelor de cereale în concordanţă cu proprietăţile fizico-mecanice ale plantelor,
Ph.D Thesys, “Transilvania” University of Braşov, 2001
[2]. Chapra, S.C., Canale, R.P., Numerical Methods for Engineers, McGraw-Hill, Inc.,
1985
[3]. Jordan, D.W., Smith, P., Mathematical Techniques, 3-rd Edition, Oxford University
Press, 2002
[4]. Moise, V., Maican, E., Moise, Şt.I., Metode numerice (Teorie şi aplicaţii). Editura
Printech, Bucureşti, 2004
[5]. Maican, E., Rădulescu, Fl., Noţiuni de programare în limbajul Turbo Pascal, Editura
Printech, Bucureşti, 1998

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