Final Presentation Raquel Ciappi Brad Miller Stephen Petfield Chris Uthgenannt.
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Transcript of Final Presentation Raquel Ciappi Brad Miller Stephen Petfield Chris Uthgenannt.
Case New Holland (CNH) is the number one manufacturer of agricultural tractors and combines
Products include: Harvesting and seeding equipment Balers Disc mowers and mower conditioners
Disc mowers are used to cut crops such as alfalfa and hay before baling
Mowers utilize 4-6 oppositely rotating blade heads aligned along a shaft underneath the mower’s hood
Under normal operating speeds blade heads rotate at 3000 rpm
A protective curtain on the mower is used to provide shielding from high-speed projectiles
Conditioning rolls are used to crush crop stems and decrease drying time
Before cutting, crops must pass by the protective curtain
Current curtain exerts a large force on crops causing a knockdown effect and lower quality cut
To eliminate this effect farmers are mowing with the mower deck in a raised position
Raised deck poses safety hazards from high speed projectiles
Identify causes of knockdown force (KDF)
Create testing methods to quantify knockdown force
Design a new shielding system to attenuate knockdown force while maintaining adequate projectile protection
Using discussions with CNH a set of wants was developed
Metrics were created as a basis for design evaluation
Possible areas for modification of existing design to decrease knockdown: Turbulent airflow underneath mower Curtain material Mounting system
Each factor is assessed using engineering analysis and conducting tests in a controlled environment
Key findings implemented in a new design prototype
Employ air vents and mesh curtain to control turbulent airflow generated by mower
Implement lighter curtain material Modify mounting configuration for hinge
system
Preliminary airflow analysis was conducted to examine turbulent airflow effects on curtain
Mower curtain modeled as a flat plate subjected to normal flow
Drag effects exert significant outward force on mower curtain (22.3 lbf)
Further experimental testing needed to fully understand airflow effects
Initial testing examined airflow effects by measuring airflow velocities using an anemometer
Measurements taken at 10 different locations along lower and upper halves of curtain
2 sets of trials conducted: Closed deck hood Open deck hood
Similar patterns seen for each testing configuration
Air velocities projected outward suggest use of mesh at high velocity locations
0
1
2
3
4
5
6
1 2 3 4 5 6 7 8 9 10
Air
flo
w (
m/s
)
Location along Opening
Airflow Measurements: No curtain, Raised Deck
Top Portion
Bottom Portion
0
1
2
3
4
5
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1 2 3 4 5 6 7 8 9 10
Air
flo
w (
m/s
)
Location along Opening
Airflow Measurements: No curtain, Lowered Deck
Top Portion
Bottom Portion
1 2 3 4 5 6 7 8 9 10
Conduct testing measuring the force needed to deflect curtain
Measurements taken with mower on and off
Measurements at 4 locations along curtain
Examines the role of airflow with respect to knockdown force
Results show airflow is a significant factor in causing crop knockdown
Another method to control airflow is implementation of vents on the mower deck
Examining blade head air direction, vents installed at optimal locations on mower deck
To evaluate vent effectiveness air velocities were measured at: Bottom of curtain Each vent location
Different vent configurations employed to examine variations in air velocity
Results suggest that no vent combination reduces air velocity
Velocities at bottom of curtain actually increased with vents
1 2 3 4 5
Computational Fluid Dynamics (CFD) performed
Confirms testing results and further explores turbulent air patterns
Simple simulation in COSMOS Flow Works
CFD results show little or no velocity near deck hood
Highest velocities point directly towards curtain
Airflow is a significant factor in crop knockdown
Testing and CFD results demonstrate that vents do not control airflow
Modifying turbulent air effects of mower is complex and not feasible
Employing mesh curtain sections still a viable method to reduce knockdown force
Curtain design consists of a non-homogenous solid material lighter than existing design
Sections of mesh material employed at areas with high air velocities
Conduct testing to: Ensure mesh passes ISO safety standards Select a material to lower knockdown
force
Modified ISO standards test to determine projectile ejection patterns
Mower curtain replaced by layers of plywood, Styrofoam, and paper
Mower pulled by tractor over piles of sand, gravel, and water mixture
Projectile ejections recorded by indentations or projectiles lodged in Styrofoam
Plywood
Styrofoam
Paper
Mower deck
Sand and gravel
Mower blades
Styrofoam divided into 6 sections
Projectile impacts were counted and separated into large and small categories
Large projectiles averaged 28 strikes per section
Indicates that solid curtain material must be used
PICTURE OF STYROFOAM GOES HERE!
Add some kind of slide so that we can transition from material to mounting without losing the audience because we haven’t discussed a way to evaluate the knockdown force of different materials
Three new mounting methods proposed:
Conventional hinge
Spring hinge
Counterweight hinge
Preliminary analysis of each hinge design was conducted to predict each system’s performance
Assuming no curtain deflection, equations were derived for each mounting system
Illustrate behavior of knockdown force with varying angle (taken from horizontal)
Basic Hinge Spring Hinge Counterweight
Derived equations wereused with approximatevalues for each parameter
Force vs. Angle graphconstructed to comparedesigns
Predicts performance ofeach mounting configuration
Spring hinge and counterweight most appealing designs
Minimizing both force and angle will produce best results
The optimal curtain material and mount need to be determined
Testing apparatus designed to quantify knockdown force of various materials and configurations under controlled conditions
Eliminates turbulent air flow variableKnockdown Force Test (KDF Test)
Apparatus utilizes load cell to measure force exerted by moving curtain assembly
Electric motor provides constant curtain speed of 0.642 mph
12 trials performed to assess forces of 4 different materials and 4 mounting systems
Motor
Load Cell
Crossbar
Lighter materials reduce knockdown force Test results similar to hand calculations Hinge designs serve to attenuate knockdown Vinyl and Polyurethane materials were too
light for spring hinge and counterweight
Vinyl and Polyurethane materials performed best but are not used
Materials cannot withstand turbulent airflow generated by mower
Single-ply curtain used on final design
INSERT VIDEO OF VINYL CURTAIN FLAPPING
Existing fixed mount produced largest knockdown force
Counterweight ideal but not used for final design More complex design Requires more parts Longer installation times
Implement conventional hinge design
Compare prototype design to original system using: Validation testing Design metrics and target values:
▪ Safety▪ Knockdown Force▪ Compatibility▪ Simplicity▪ Production Cost
Curtain assembly performance test evaluates new design
Full scale validation test Measured the force of 2” inward curtain
deflection with mower on and off Force measurements recorded for:
Hinged single-ply Fixed single-ply Fixed double-ply
Hinged single-ply yielded lowest force values Confirm key findings of KDF test Validates final design
New design uses material which passes ISO safety tests
Reduction in knockdown force by .4559 lbf
Compatible and simple design Small increase in production cost per unit
Item Cost Quantity Total Cost
Hinges $1.50 6 $9.00
Curtain $23.40 1 $23.40
Hardware $.05/piece 12 $0.60
Assembly$.50/fastener 6 $3.00
$1.00/weld 6 $6.00
Total $42.00
Item Cost
Steel $100.00
Aluminum $40.00
Curtain Materials $132.08
Hinges $41.58
KDF Motor $57.44
Etch Test Supplies $81.26
Hardware $50.00
Misc. Items $105.53
Lab VIEW Data Acquisition Program*
$4000.00
Load Cell* $300.00
Machine Shop Labor $850.00
Labor $6375.00
Total Project Cost $12,132.89
*=not actually purchased by team