A reliable film breaking control method in the film winding process of a round bale cotton picker

Abstract

A reliable film breaking control method in the film winding process of a round bale cotton picker, comprising obtaining a nominal film feeding tooth number, which refers to the number of film feeding teeth from the start of film winding to film breaking of the round bale cotton picker, and a photoelectric rotation speed sensor detects the pulse number output by a gear coaxial with a film feeding roller, with one pulse signal output per tooth rotation; in the film winding process, the real-time actual film feeding tooth number is obtained and compared with the nominal film feeding tooth number, and if it is less than a preset error range and a label is detected, or it is greater than a preset upper deviation, film breaking processing is performed, otherwise, even if a label is detected, film breaking processing is not performed. According to the comparison between the actual film feeding tooth number and the nominal film feeding tooth number in the film winding process, the present application realizes reliable control of the film breaking position.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of agricultural machinery automation, in particular to a reliable film breaking control method in the film winding process of a round bale cotton picker. BACKGROUND

[0002] The cotton picker is an indispensable cotton picking and harvesting machine in large cotton fields, which can greatly improve the cotton picking efficiency, reduce the labor intensity of cotton farmers and save labor costs. At present, the cotton picking rate in China has reached more than 80%. The cotton picker is generally divided into a box type cotton picker and a round bale cotton picker. The round bale cotton picker can realize cotton picking, conveying, cotton collecting, packaging, film winding, and non-stop unloading and packaging combined operation, has higher comprehensive picking efficiency, improves the safety of cotton storage, reduces the transportation cost, and is more and more popular in the cotton producing area.

[0003] In the film winding process of the round bale cotton picker, a certain length of bale film is sent into the packaging belt by the film feeding mechanism, and then the bale film is wrapped around the cotton bale to complete the film winding by the packaging belt. Accurate film breaking is the key to the success of the film winding process. Too late film breaking will cause too much film feeding and blockage, or waste caused by feeding multiple bale films. Too early film breaking will cause the next bale film to be unable to feed.

[0004] The existing technical solution generally pastes an opaque label at the end of each bale film, detects the position of the label by using a laser light emitting and receiving sensor, and then breaks the bale film after a certain time delay or a certain number of film feeding teeth. This solution has two shortcomings. On the one hand, before the label arrives, the label detection sensor may output an incorrect detection signal due to interference by other foreign objects, resulting in premature film breaking. On the other hand, the label detection sensor may not detect the label even after a bale film is finished, resulting in feeding of multiple bale films. SUMMARY

[0005] The present application aims to overcome the shortcomings of the prior art and provides a reliable film breaking control method in the film winding process of a round bale cotton picker. The nominal film feeding tooth number parameter is introduced in the film winding process, and the nominal film feeding tooth number is automatically obtained by statistical analysis based on historical data. In the film winding process, the actual film feeding tooth number and the nominal film feeding tooth number are compared to reliably control the film breaking position.

[0006] The technical scheme adopted by the present application is as follows:

[0007] A reliable film breaking control method in the film winding process of a round bale cotton picker, the round bale cotton picker comprising a photoelectric speed sensor, a label detection sensor, a packaging controller, and a vehicle-mounted monitoring display instrument, characterized in that it comprises the following steps:

[0008] S1. Obtain a nominal film feeding tooth number, which refers to the number of teeth of a gear coaxial with a film feeding roller detected by a photoelectric rotation speed sensor from the start of film winding to film breaking of a round bale cotton picker;

[0009] S2. During the film winding process, obtain a real-time actual film feeding tooth number, and compare it with the nominal film feeding tooth number. If the actual film feeding tooth number is less than a preset error range and a label is detected, or the actual film feeding tooth number is greater than a preset upper deviation, film breaking is performed, otherwise, even if a label is detected, film breaking is not performed.

[0010] Further, the step S1. obtains the nominal film feeding tooth number N0, and specifically comprises:

[0011] Mode one, manual setting; or

[0012] Mode two, automatic calculation, comprising:

[0013] S1.1. Set a nominal film feeding tooth number counting array N[M], M is the number of recorded data, and M≥3,

[0014] S1.2. Set an initial serial number n=0;

[0015] S1.3. When it is detected that the diameter of a cotton bale reaches a preset diameter, start the film winding process, and clear the nth round of film feeding tooth number, i.e. N[n]=0;

[0016] S1.4. Collect a pulse signal, and update the current film feeding tooth number, i.e. N[n]=N[n]+1, until a label at the end of the film is detected;

[0017] S1.5. Record the current film feeding tooth number N[n], and determine whether the current film feeding tooth number N[n] is valid, i.e. determine whether there is an abnormality in the current film winding process. If yes, discard the recorded film feeding tooth number value, and return to step S1.3, otherwise, record the film feeding tooth number as a valid one, and proceed to step S1.6;

[0018] S1.6. Start the next round of film feeding tooth number recording, i.e. n=n+1, and return to step S1.3, until n=M, and proceed to step S1.7;

[0019] S1.7. Calculate the average value or the median value of N[0]~N[M-1] as the nominal film feeding tooth number N0.

[0020] Further, the step S2. specifically comprises:

[0021] S2.1. Set an actual film feeding tooth number counting value Nn;

[0022] S2.2 detects and judges whether the cotton ball diameter reaches the preset diameter, when the cotton ball diameter reaches the preset diameter, the film winding process is started, and the actual film feeding tooth count value is cleared, that is, Nn=0;

[0023] S2.3 acquires a pulse signal, and when a pulse signal is acquired, the current film feeding tooth count value is updated, that is, Nn=Nn+1;

[0024] S2.4 sets the film feeding tooth number upper deviation δ1, and judges, if Nn>(N0+δ1), the film is started to be broken, and step S2.6 is entered, otherwise step S2.5 is entered;

[0025] S2.5 sets the film feeding tooth number lower deviation δ2, and judges, if Nn<(N0-δ2), the step S2.3 is returned, otherwise step S2.6 is entered;

[0026] S2.6 judges whether the label at the end of the film winding is detected, if not, the step S2.3 is returned, otherwise step S2.7 is entered;

[0027] S2.7 starts to break the film, and returns to step S2.2 until the cotton picker is turned off.

[0028] Compared with the prior art, the advantages of the present application are that:

[0029] The present application can exclude the abnormal interference of false label signals, and can break the film in time when missing detection occurs, avoid the problems of too early or too late film breaking, reduce the abnormal shutdown of the cotton picker, and improve the reliability and working efficiency of the cotton picker. BRIEF DESCRIPTION OF DRAWINGS

[0030] Figure 1 is a nominal film feeding tooth automatic calculation flowchart.

[0031] Figure 2 is a reliable film winding process film breaking flowchart. DETAILED DESCRIPTION

[0032] The technical solutions of the present application will be further described below in combination with the drawings and examples. Obviously, the described examples are only part of the examples of the present application, not all examples. Based on the examples in the present application, all other examples obtained by those skilled in the art without creative labor belong to the scope of protection of the present application.

[0033] A certain type of round bale cotton picker as an example, its control system includes a touch function of the vehicle monitoring display instrument, packing controller, monitoring controller, vehicle monitoring display instrument and each control unit through CAN bus connection. Detection of the film label photoelectric tag sensor and packing controller connection, no detection of the label, output low, detected label output high. Detection of the film tooth number of photoelectric speed sensor and packing controller connection, the photoelectric speed sensor can real-time detection of the film roller coaxial installation of the gear teeth, when the film roller rotation, every turn 1 tooth, the photoelectric speed sensor output a pulse signal to the packing controller. Vehicle monitoring display instrument has a man-machine interface can be manually started nominal film tooth number calculation, also can show the end of each film winding film tooth number, and can be artificially determined the current film tooth number for valid or invalid.

[0034] A round bale cotton picker reliable film breaking control method contains two steps:

[0035] (I) first need to manually set the nominal film tooth number N0, the nominal film tooth number N0 is a winding film from the start winding to the film breaking film grinding roller rotation of the tooth number, the tooth number is the photoelectric speed sensor detection and film grinding roller coaxial gear output pulse, every turn 1 tooth output 1 pulse.

[0036] Or, automatically calculate the nominal film tooth number N0:

[0037] 1. Vehicle monitoring display instrument from the man-machine interface to receive the start nominal film tooth number automatic calculation instruction, and send the start instruction through the CAN bus to the packing controller, the packing controller start calculation of the nominal film tooth number.

[0038] 2. In the program of the packing controller to set a film tooth number count array N[M], up to M data can be recorded, in this embodiment, M = 3, that is, N[0], N[1], N[2];

[0039] 3. Set the serial number n = 0;

[0040] 4. The packing controller constantly judges whether to meet the winding conditions, if the winding conditions are met, start winding, and N[n] is cleared, that is, N[n] = 0. Among them, the winding condition is the real-time bale diameter ≥ set diameter.

[0041] 5. In the process of winding, the packing controller collects a photoelectric speed sensor pulse signal every time, and adds 1 to N[n].

[0042] 6. When the packing controller detects the high level signal of the label sensor, the current N[n] value is recorded and sent to the vehicle-mounted monitoring display instrument, and displayed on the human-computer interaction interface. The effective signal of the label sensor can be high level or low level, and the invalid signal is low level or high level.

[0043] 7. The vehicle-mounted monitoring display instrument receives the judgment instruction from the human-computer interaction interface about whether the current recorded N[n] value is valid or invalid, and sends the judgment instruction to the packing controller. If the packing controller receives the judgment valid signal, go to step 8, otherwise go to step 4.

[0044] 8. n = n + 1, if n < 3, go to step 4, otherwise go to step 9.

[0045] 9. The packing controller calculates the average value of N[0], N[1], N[2], and assigns the average value to the nominal film feeding tooth number N0. The value of N0 is saved to the non-volatile memory.

[0046] 10. The packing controller sends the nominal film feeding tooth number N0 to the vehicle-mounted monitoring display instrument, and the vehicle-mounted monitoring display instrument displays the N0 value on the human-computer interaction interface, and displays the prompt "nominal film feeding tooth number calculation success". The automatic calculation of the nominal film feeding tooth number is completed.

[0047] In step 9, the median value of N[0], N[1], N[2] can also be calculated, and the median value is assigned to the nominal film feeding tooth number N0 as the nominal film feeding tooth number.

[0048] (II) After obtaining the nominal film feeding tooth number N0 through the above steps, the following steps are used to realize reliable film breaking in the subsequent film winding process.

[0049] 1. Set an actual film feeding tooth number count value Nn in the program of the packing controller.

[0050] 2. The packing controller continuously judges whether the film winding condition is met. If the film winding condition is met, the film winding is started, and Nn is cleared, i.e. Nn = 0.

[0051] 3. During the film winding process, the packing controller adds 1 to Nn for each photoelectric speed sensor pulse signal collected.

[0052] 4. If Nn > (N0 + δ1), although no label is detected, the packing controller also starts the film breaking program, and goes to step 7. Otherwise, go to step 5. Wherein δ1 is the film feeding tooth number upper deviation, and δ1 = 15 in this embodiment.

[0053] 5. If Nn < (N0- δ2), go to step 3, in this process, the packaging controller ignores the label signal even if it is detected. Otherwise go to step 6. Where δ2 is the lower deviation of the film feeding teeth number, δ2 is 10.

[0054] 6. The packaging controller goes to step 3 if no label is detected; otherwise, if a label is detected, go to step 7.

[0055] 7. The packaging controller starts the film breaking procedure, after the film is broken, go to step 2. Cycle until the machine is turned off.

[0056] The above embodiment can obtain a more accurate nominal film feeding teeth number, in the subsequent film winding process, the abnormal interference of the false label signal can be excluded, and when a missed detection occurs, the film can be broken in time, the problems of too early or too late film breaking can be avoided, and reliable control of the film breaking position can be realized.

[0057] The above only describes the embodiments of the present application, and does not limit the patent range of the present application, any equivalent structure or equivalent process transformation using the content of the present application, or direct or indirect application in other related technical fields, are also included in the patent protection range of the present application.

Claims

1. A reliable method for controlling film breakage during the wrapping process of a round-bundle cotton harvester, characterized in that, Including the following steps: S1. Obtain the nominal number of film feeding teeth N0. This nominal number of film feeding teeth refers to the number of pulses output by the photoelectric speed sensor of the gear coaxial with the film feeding roller from the start of film wrapping to the film breaking of the round-type cotton harvester. One pulse signal is output for each tooth that rotates. S2. During the wrapping process, the real-time actual number of film feeding teeth is obtained and compared with the nominal number of film feeding teeth. If it is less than the preset error range and a label is detected, or greater than the preset upper deviation, film breaking is performed; otherwise, film breaking is not performed even if a label is detected. Step S2 specifically includes: S2.1 Set the actual film feeding tooth count value Nn; S2.2 Detect and determine whether the diameter of the cotton bale has reached the preset diameter. When the diameter of the cotton bale reaches the preset diameter, start the film wrapping process and clear the actual film feeding tooth count value, i.e., Nn = 0. S2.3 Acquire pulse signals. When a pulse signal is acquired, update the current count value of the number of film feeding teeth, i.e., Nn = Nn + 1. S2.4 Set the deviation δ1 of the number of film feeding teeth and determine if Nn>(N0+δ1). If so, start the film breaking and proceed to step S2.6; otherwise, proceed to step S2.

5. S2.5 Set the lower deviation δ2 of the film feeding tooth count and determine if Nn < (N0 - δ2). If so, return to step S2.3; otherwise, proceed to step S2.

6. S2.6 Determine whether a label at the end of the capsule is detected. If not, return to step S2.3; otherwise, proceed to step S2.

7. S2.7 Initiate film breaking and return to step S2.2 until the cotton harvesting machine shuts down.

2. The reliable film breakage control method during the film wrapping process of the round-type cotton harvester according to claim 1, characterized in that, Step S1, obtaining the nominal number of film feeding teeth N0, specifically includes: Automatic calculation, including: S1.1 Set the nominal film feeding tooth count array N[M], where M is the number of records, and M≥3. S1.2 Let the initial sequence number n = 0; S1.3 When the diameter of the cotton bale is detected to reach the preset diameter, the wrapping process is started, and the number of feeding teeth in the nth round is cleared, i.e., N[n] = 0; S1.4 Acquire pulse signals. When a pulse signal is acquired, update the current number of film feeding teeth, i.e., N[n] = N[n] + 1, until the label at the end of the film is detected; S1.5 Record the current number of film feeding teeth N[n] and confirm whether the current number of film feeding teeth N[n] is valid, that is, confirm whether there is any abnormality in this film wrapping process. If so, discard the recorded number of film feeding teeth and return to step S1.

3. Otherwise, record it as a valid number of film feeding teeth and proceed to step S1.

6. S1.6 Start recording the number of film feeding teeth in the next round, i.e., n = n + 1, return to step S1.3, until n = M, and proceed to step S1.7; S1.7 Calculate the average or median value of N[0] to N[M-1] as the nominal number of film feeding teeth N0.

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