second periodic report annex: pictures and tables...second periodic report annex: pictures and...

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Grant Agreement number: 315416

Project acronym: ROD-PICKER

Project title: ROD-PICKER— Automatic harvesting system for SRC nurseries

Second periodic report

Annex: Pictures and tables

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3.1 Publishable summary

Figure 1: The harvesting module during field tests in early 2014

Figure 2: General view of the sorting, cutting and bundling module

3.2 Core of the report for the period: Project objectives, work progress and

achievements, project management

3.2.2 Work progress and achievements during the period

Work package 2: Development and design of the ROD-PICKER prototype

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Figure 3: Measuring and Cutting Component Schematics: 1 - air cylinder for

blade powering; 2 - blade and it’s support and guiding; 3 - cutting skeleton; 4 – rotary wheels for belt movement; 5,6,7 – rod guiding wheels (fixed and mobile); 8 – fixing spring; 9 - opposite blade ensemble; 10,11 – frame components; 12 – processed rod

Figure 4: Actual implementation of the Measuring and Cutting Component

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Figure 5: Presentation and description of Supporting

Functions

S4 - Energy

supply

S5 -

Compressed

air supply

Ensures the continuity of the process

Ensures the frequency of the process

Ensures the functionality of the process

Compatibility (internal & external)

Ensures & converts energy for

technological effects & diagnosis

Ensures the functionality of the process

Ensures the synchronization of

functions

Controls of the operating parameters

Ensures the security of working process

S1- Guidance

and driving

Stems

S2 - Functions

correlation

S3 - Self

diagnosis

S6 - Monitoring-

Integrating

Ensures continuity and speed in the

process

Leads and prepares the stems for

cutting

Leads and prepares the stems for

sorting

Checking of errors

Ensures safety & health

Checking of the operating parameters

Automation and optimization of

functional steps

Ensures constant air pressure, quality &

flow for cutting process

SUPPORTING

FUNCTIONS

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Figure 6: Presentation and description of Basic Functions

BASIC

FUNCTIONS

Measures the stem diameter with values

between 25-7 mm Ensures the working accuracy

Ensures the work space

Measures the stem length with values

between 2350 - 1200 mm

Ensures the working accuracy

Ensures the working speed

Ensures the cutting speed

Ensures the cutting accuracy


Achieves a full cutting process

Ensures the speed detection


Ensures the cutting accuracy

Achieves a full cutting process

Ensures the cutting speed

Removes the branches


Easy to handle

Low noise

Ensures a healthy work environment

Ensures a secure work environment


Rhythmicity of the process


Selectivity in the process

Compatibility between the cutting unit and the

conveyor

Insuring stem’s run

Rhythmicity in the process

F1 - Diameter

measurement

F2 - Length

measurement

F3 - Cutting on Diameter/

Length

F4 - Length

measurement

F5 - Cutting

before Branches

F7 - Providing

quality and health

assurance

F8 - Stem supply

F9 - Product

ejection

F6 - Providing

ergonomic

conditions

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Figure 7: Schematics (a) and built version (b) of the prototype Unit at the beneficiary

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Figure 8: Electric cabinet near off cutting head and detail of electric panel indicator disposed

Figure 9: Tests performed at the facilities of LEMPE

Achievements:

D 2.05 Designed prototypes

Planned delivery date: August 2013

Actual delivery date: 27.05.2014

Use of resources:

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Work package 3: Construction and initial tests of the ROD-PICKERprototype

Figure 10: Left: welded main frame / Right: mounting the side flap

Figure 11: partially assembled prototype ready for lacquering

WP2

Partner Planned

Spent on

the first

period

Spent on

second

period

EGEDAL 3,00 1,50 1,78 11.520,00 € - € - € - € 11.520,00 € 6.912,00 € 18.432,00 €

SALIX 2,50 1,50 1,58 9.247,43 € - € - € 2.083,01 € 11.330,44 € 6.798,26 € 18.128,70 €

LEMPE 3,00 1,50 2,30 8.740,00 € - € - € 109,78 € 8.849,78 € 5.309,87 € 14.159,65 €

TUD 16,00 7,00 9,00 52.658,28 € - € 711,39 € - € 53.369,67 € 32.021,80 € 85.391,47 €

UPT 17,75 5,77 12,22 29.955,00 € - € 29.955,00 € 17.973,00 € 47.928,00 €

ttz 7,00 4,23 2,38 25.680,00 € - € - € 25.680,00 € - € 25.680,00 €

Personnel Costs (€) Subcontract

Consumables,

Equipment

and Prototype

Travel &

SubsistenceTotal direct costs Overheads Total costs (€)

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Figure 12: Left: Installation of the hydraulic system, right: gear box with hydraulic

pumps

Figure 13: left: Switching unit with relays, right: ROD-PICKER operation terminal

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Figure 14: Finished ROD-PICKER prototype V1.1

1) Lower link connection with

swing gear

2) Saw blades

3) Draw bar with drive shaft

4) Power take-off gear with

hydraulic pumps

5) Top cutter

6) Collecting unit with feeder belts

7) Loading platform

8) Side gate

Figure 15: Operation terminal

Figure 16: external dimensions ROD-PICKER prototype

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Table 1: external dimensions

A Length [mm] 7.261

H Transport Height [mm] 2.578

B Width [mm] 2.583

T Track gauge [mm] 1.500

K Length of the load platform [mm] 3.770

Curb weight [kg] 2.900

permitted total weight [kg] 4.400

permitted axle load [kg] 4.000

Drawbar load [kg] 650

Table 2: Power requirements and needed connections

Power requirements / Connections of the tractor

Max transportation speed on street 25 km/h

Power requirement tractor Min. 60 kW

PTO speed 540 - 780 U/min

Current supply light 12 V, 7-pin electrical outlet (ISO 1724)

Current supply operating terminal 12 V, 3-pin electrical outlet

Hydraulic connection 1 x pressureless outlet flow

Oil flow Max. 30 l/min

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o

o

o

o

o

o

o

o

o

o

o

o

o

Figure 18: Detail of the cutting device

Figure 19: Detail of the cutting device

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Figure 20: Powering device, responsible for rod displacement and movement

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Figure 21: Omron 32 fixed at the second cutting structure and Figure 22: Omron E6B2-CWZ5B encoders

Figure 23: Final structure of machine control system

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Figure 24: early prototype of the control unit

Figure 25: Finalized prototype ready for new tests

Achievements

D 3.06 Report on fully automatically running software and

data check

Planned delivery date: October 2013


Use of resources

WP3

Partner Planned

Spent on

the first

period

Spent on

second

period

EGEDAL 1,50 3,25 1,78 11.520,00 € - € - € 863,65 € 12.383,65 € 7.430,19 € 32.197,49 €

SALIX 1,50 0,25 1,39 8.918,23 € - € - € 663,10 € 9.581,33 € 5.748,80 € 15.330,13 €

LEMPE 1,50 0,75 1,65 6.270,00 € - € - € 49,70 € 6.319,70 € 3.791,82 € 10.111,52 €

TUD 11,50 4,73 6,11 22.005,67 € - € 43.913,53 € 837,87 € 66.757,07 € 40.054,24 € 106.811,31 €

UPT 12,00 10,00 3,22 8.895,00 € - € - € 8.895,00 € 5.337,00 € 14.232,00 €

ttz 10,00 0,00 10,56 114.080,00 € - € 470,92 € 2.120,55 € 116.671,47 € 83.278,40 € 199.949,87 €

Overheads Total costs (€)Personnel Costs (€) Subcontract

Consumables,

Equipment

and Prototype

Travel &

SubsistenceTotal direct costs

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WORK PACKAGE 4: On/site testing and optimization of the ROD/PICKER prototzpe at a

tree nursery farm, monitoring and evaluation

Figure 26: Experimental plan for the field tests

Figure 27: left: pressure sensors, right: oil flow sensor

Figure 28: Measurement terminal (Hydrotechnik 8050)

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Figure 29: Initial test ROD-PICKER harvester January 2014 at TUD

Table 3: No-load power of the different drives

PTO speed [rpm]

Saw blade drive [kW]

Top cutter drive [kW]

Collecting belts drive [kW]

Unloading belts drive [kW]

580 4.85 0.47 1.46 1.07

680 5.68 0.53 1.68 1.30

780 6.88 0.59 1.98 1.33

Figure 30: Overview SRC nurseries in Saxony, Germany

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Figure 31: Measuring section Seifersdorf

Figure 32: Left:Test run Seifersdorf (11 km/h), Right: Cut view 96 teeth saw blad 5 km/h

Figure 33: Loaded harvester prototype (500 m willow single row)

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Figure 34: Left: Power requirement of the feeder belt drive, Right: feeder belt drive with rods

Figure 35: Left 64 teeth without carbide plates, Right: 96 teeth with carbide plates

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Figure 36: Cutting performance by a saw blade speed of 1208 rpm

Figure 37: cut 5 year old rootstock with 100 mm length

Figure 38: Determination of the maximum oil pressure and cut performance

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Table 4: Relation harvest speed and total crop performance

Example: 1) 4 rods per rootstock, 0.3 m planting distance)

2) Crop performance without any ancillary times, Row length: 400 m, distance

between the rows: 2 m

3) Ancillary times for each row, Unloading on headland: 1 min, Transport time: 1

min, Service time: 0.5 min

Figure 39: Left: Simply supported lower link mount, Right: FEM analysis main frame

Figure 40: Left: angular adjustment, Right: new ground plate for the saw blade

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Figure 41: Design study for a double-row harvester

By integrating a second cutting and feed-in unit, the harvesting capacity could be doubled with

Fig 42: Initial mechanical test of the cutting system

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Figure 42: First test of the sensor system at UPT

Figure 43. Picture of the test runs of the inverter with connected 3 phase transformer

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Figure 44: Demonstration and test of the cutting system prototype

Figure 45: Cutting system with motion control

Motor

Motion wheels

Pneumatic cutting

system

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Figure 46: Drive system with motion sensor

Figure 47: Camera system in the prototype

Incremental

Motion sensor

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Figure 48: Picture of the camera system during the tests

Figure 49: Lab tests at UPT with conveyor system

A

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Figure 50: Prototype for first practical test at Lempe

Figure 51: High quality cut of a poplar rod on the conveyor

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Figure 52: Housing of the cutting module

Figure 53: Feeding indicator and display for the sensor data

Also the data display of the sensor data improved the system. The display shows data of the

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Figure 54: Light barrier and air pressure system on the first stage of the band conveyor

Figure 55: In the test prepared bundles of rods

Measurement Processing time for the bundle in minutes

Notes

1 6:55 With manual bundling

2 6:30 2 cleaning interruptions (each ca 15s) without bundling

3 6:15 3 cleaning interruptions, without bundling

4 6:40 3 cleaning interruptions, without bundling

5 6:45 Several interruptions

Table 5: Several times recordings for production of 50 rod bundles

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Figure 56: Programming and monitoring of the PLC by the programming software

Figure 57: Diameter control of the processed rods

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Figure 58: Control of the length of the rods after processing

Figure 59: parts of the data recording forms of the harvesting unit

Achievements

D 4.07 Protocols on system operation performance

Expected: October 2013

Submission date: 30.09.2013

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Use of resources

WORK PACKAGE 5: Sustainability assessment on the ROD-PICKER system

Objectives:

Figure 60: General principle of the whole process from harvesting to delivery

WP4

Partner Planned

Spent on

the first

period

Spent on

second

period

EGEDAL 1,00 0,00 1,19 7.680,00 € - € - € 357,00 € 8.037,00 € 4.822,20 € 20.896,20 €

SALIX 0,75 0,00 1,30 7.081,21 € - € - € 795,28 € 7.876,49 € 4.725,89 € 12.602,38 €

LEMPE 3,25 0,00 3,42 12.996,00 € - € - € 30,45 € 13.026,45 € 7.815,87 € 20.842,32 €

TUD 5,50 0,00 11,47 57.429,63 € - € 18.252,65 € 430,97 € 76.113,25 € 45.667,95 € 121.781,20 €

UPT 5,50 0,00 13,82 34.430,00 € - € 43.363,30 € 13.892,52 € 91.685,82 € 55.011,49 € 146.697,31 €

ttz 5,00 0,00 6,10 65.880,00 € - € 2.710,11 € 1.564,84 € 70.154,95 € 48.092,40 € 118.247,35 €

PM


Consumables,

Equipment

and Prototype

Travel &


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Figure 61: screenshot of openLCA software with parts of the developed product system

Table 6: key data of the harvesting module of the ROD-PICKER system

Table 7: key data of the sorting and bundling module of the ROD-PICKER system

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Figure 62: Planting layout of the example and storage positions

Table 8: Cost comparison between manual harvest and ROD-PICKER harvester

Manual harvest

with brush cutter ROD-Picker Optimization

Staff 4 Back staff (20 Mh

/ha)

1 Expert (1,25

Mh /ha) Reduced by 94 %

Crop performance: ~ 0,2 ha/h ~ 0,8 ha/h Increased by 300 %

Staff costs ~ 240 € / ha ~ 20 € / ha Reduced by 91 %

Technique costs

(inkl. 80 kW tractor) ~ 135 € / ha ~ 202 € / ha Increased by 50 %

Overall costs ~ 449 € / ha ~ 243 € / ha Reduced by 46 %

Figure 63: Cost comparison between manual harvest and ROD-PICKER harvester

For a better illustration, the cost pools of the two process variants are depicted next to each

Figure 64: Cost comparison between Fröebbesta harvester and ROD-PICKER harvester

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Figure 65: Canvas model for the first business

Achievements:

D 5.08 Report on overall assessment and economic feasibility

study

Planned delivery date: September

2014



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D 5.09 Evaluation of the prototype performance

D 5.10 Report on training activities and business analysis

2014



2014


Use of resources:

Work package 6: Dissemination and exploitation

Objectives: The aim of this work package is to disseminate the project results for the later

Figure 66: Welcome of the workshop attendees during the workshop activities in Germany

WP5

Partner Planned

Spent on

the first

period

Spent on

second

period

EGEDAL 1,75 0,00 2,07 13.440,00 € - € - € 370,00 € 13.810,00 € 8.286,00 € 35.906,00 €

SALIX 1,75 0,00 1,69 11.108,35 € - € 411,41 € 2.314,44 € 13.834,20 € 8.300,52 € 22.134,72 €

LEMPE 1,75 0,00 1,75 6.650,00 € - € - € 291,22 € 6.941,22 € 4.164,73 € 11.105,95 €

TUD 2,25 0,00 2,50 10.317,80 € - € 493,90 € 161,48 € 10.973,18 € 6.583,91 € 17.557,09 €

UPT 3,00 0,00 5,47 11.200,00 € - € - € - € 11.200,00 € 6.720,00 € 17.920,00 €

ttz 4,50 0,00 6,99 75.440,00 € - € - € - € 75.440,00 € 55.071,20 € 130.511,20 €

Total direct costs

PM


Consumables,

Equipment

and Prototype

Travel &

SubsistenceOverheads Total costs (€)

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Two project leaflets

Figure 68: Front and back of the second ROD-PICKER leaflet

Figure 67:Screenshot of the project’s website

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Figure 69: Screenshot of the ROD-PICKER video publication on youtube.com

Figure 70: screenshot of the video produced by UPT for explaining the sorting and bundling unit

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Figure 71: Prof. Dumitru Tucu of the UPT explains the developed cutting and sorting subunit of the sorting and bundling unit to the Romanian TV-team

(a)

(b)

Figure 72: presentation of project ROD-PICKER during conference and exhibition in Baia Mare (Romania) (a) and on the InnoMatch-Fair in Arad (Romania) (b)

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(a). (b)

Figure 73: First two pages of the article in the "Energie aus Pflanzen"-magazine (a) and article in TASPO (b)

Achievements

D 6.13 “Publications in relevant magazines, presentations and

demonstration material for trade fairs”

D 6.14 “Final plan for the use and dissemination of the knowledge”

Expected: September 2014


Expected: September 2014


Use of resources

WP6

Partner Planned

Spent on

the first

period

Spent on

second

period

EGEDAL 2,50 0,00 2,96 19.200,00 € - € 2.430,00 € - € 21.630,00 € 12.978,00 € 34.608,00 €

SALIX 2,25 0,89 2,03 9.309,85 € - € 193,90 € - € 9.309,85 € 5.585,91 € 14.895,76 €

LEMPE 3,50 0,50 3,00 11.400,00 € - € - € - € 11.400,00 € 6.840,00 € 18.240,00 €

TUD 0,50 0,00 0,51 2.609,24 € - € 90,05 € - € 2.609,24 € 1.565,54 € 4.174,78 €

UPT 0,50 0,00 0,94 2.720,00 € - € - € - € 2.720,00 € 1.632,00 € 4.352,00 €

ttz 0,50 0,01 1,04 11.232,00 € - € - € - € 11.232,00 € 8.199,36 € 19.431,36 €

Personnel Costs (€) Subcontract ConsumablesTravel &


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second periodic report annex: pictures and tables...second periodic report annex: pictures and...

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