Journal of Agricultural Machinery (Dec 2024)
Design, Construction, and Evaluation of an Automatic Feeder Control System for Sugarcane Billet Planters
Abstract
IntroductionThis study investigated the development and evaluation of an automatic feeder control system for sugarcane planters. The primary objective was to address limitations in existing machines and enhance their performance by introducing precise control of cane feeding.Materials and MethodsThe automatic feeder control system was equipped with three types of sensors, including a Load Cell Sensor that directly measures the weight of sugarcane on the feeder table. This feature provides a real-time assessment of cane availability. The Hydraulic Oil Pressure Sensor monitored the pressure within the hydraulic system that drives the feeder mechanism. Variations in pressure served as an indirect measure of the force applied to the cane during the feeding process. The Ultrasonic Distance Sensor employed ultrasonic waves to estimate the distance between the sensor and the sugarcane pile. Nevertheless, some limitations concerning accuracy and response time were identified. A microcontroller served as the central processing unit, receiving sensor data and generating control signals to regulate the feeder mechanism. This allowed for automation and eliminated the need for a manual operator. The performance of the automatic feeder control system was evaluated against a manual control method operated by a human.Results and DiscussionThe evaluation focused on three key aspects: cane spillage, planting quality, and control stability. Cane Spillage: the amount of sugarcane inadvertently dropped during the planting process. Automatic control methods using a load cell and hydraulic oil pressure sensor reduced spillage similarly to manual control, averaging approximately 8.8 t ha-1. The ultrasonic sensor resulted in significantly lower spillage, achieving 7.4 t ha-1. However, its limited accuracy and responsiveness led to undesirable gaps between the planted canes. Planting Quality: The implementation of automatic control techniques utilizing load cells and hydraulic oil pressure sensors successfully ensured uniform spacing between planted canes, achieving results comparable to traditional manual methods. Due to its shortcomings, the ultrasonic sensor created gaps between the planted canes, undermining the overall quality of the planting process. Control Stability: The method utilizing hydraulic oil pressure sensors exhibited limitations in maintaining consistent control under varying operational conditions. This stemmed from temperature-dependent changes in oil viscosity, which affected the pressure readings and ultimately the control signal. Based on the evaluation results, the load cell control method emerged as the most favorable option for automatic feeder control. It delivered performance that matches manual control in terms of cane spillage reduction and planting quality, all while eliminating the need for an operator. The hydraulic oil pressure sensor method, although effective in some aspects, presented challenges due to oil viscosity variations. The ultrasonic sensor showed promise for reducing spillage; however, it ultimately fell short due to its inability to accurately and swiftly detect the availability of cane, resulting in gaps between planted canes. A separate assessment was carried out to compare manual cultivation with an automatic control method based on weight measurements using a load cell. This evaluation revealed significant differences (p < 0.01) in billet weight, the number of billets utilized, and one-sided gaps between the two methods. However, no significant difference was observed in terms of two-sided gaps.ConclusionThis study successfully designed and implemented an automatic feeder control system for sugarcane planters. The load cell control method emerged as the most effective solution, successfully eliminating the need for operators while ensuring high standards of planting quality and efficiency. Additional research could explore advancements in sensor technology and control algorithms to further enhance the performance of automatic feeder control systems.AcknowledgmentThe authors would like to express their gratitude to the Managing Director of Farabi Agro-Industrial Company and its staff, as well as the technical staff of Poya Sazan Sabz Avane Company, who cooperated in the preparation and evaluation stages of the system. Vice Chancellor for Research and Technology of Shahid Chamran University of Ahvaz, Iran: financial support under the special research grant number SCU.AA98.505.
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