Parameter optimization and performance analysis of a dual-axis rotary sugarcane de-trashing and feeding mechanism using DEM–RFC coupled simulation

Abstract

The de-trashing operation and uniform feeding of sugarcane stalks into the processing inlet are the important yet under-researched stages of mechanized harvesting. This study introduces a new Dual-Axis Rotary De-Trashing and Feeding Mechanism (DATFM) system that is proposed for medium capacity chopper harvesting machine used under dense tropical field conditions and analyzed. A coupled Discrete Element Method – Rigid Flexible Coupling (DEM – RFC) simulation model has been created in EDEM 2022 and ADAMS 2023 to capture the interactive behavior between the leaf-trash particles, flexible stalk elements and the rigid rotating rollers. Based on the kinematics and the force analysis, the key parameters that affect the performance of the de-trashing and feeding process (inter-roller gap width (G), primary roller rotational speed (n₁), secondary roller inclination angle (β₂), and roller surface groove depth (d)) were identified and optimized systematically by simulation evaluation. Under a forward harvesting speed of 0.60 m/s, the optimized DATFM used to remove trash, achieved 88.1% trash removal rate (TRR) and 2.8% stalk damage rate (SDR), and feeding uniformity index (FUI) was 0.83. The TRR was 18.6 percentage points higher than the original design while the SDR was 41.7 percentage points lower, and the FUI was 36.1 percentage points higher. One-way ANOVA was performed and found that there were statistically significant differences between all of the parameter levels (p < 0.01). The model, DEM–RFC, was found to be reliable in predicting its performance for TRR by the field trials conducted during three harvesting seasons in Maharashtra, India with a mean absolute simulation-to-field error of 4.12%. The results offer a mechanism-driven framework for DATFM parameter redesign that can be replicated, and further the sugarcane harvest equipment simulation knowledge base for the tropical regions.