Design and Simulation Test of the Control System for the Automatic Unloading and Replenishment of Baskets of the 4UM-120D Electric Leafy Vegetable Harvester

This study designed a control system for the automatic unloading and replenishment of baskets based on the cooperative detection of photoelectric sensors and pressure sensors based on analyzing the structure of the 4UM-120D electric leafy vegetable harvester. The goal of this study was to increase the operation efficiency of leafy vegetable harvesters and decrease the work intensity of operators. A control system for the automatic unloading and replenishment of baskets based on the cooperative detection of a photoelectric sensor and pressure sensor was designed and constructed after an analysis of the operating principle and system components of automatic basket unloading and basket replenishment control at the rear of the harvester. The bench test results showed that the bottom photoelectric sensor and top photoelectric sensors 1 and 2 on the touch screen were not lit and the pressure sensor value was displayed as −0.00075531 kg, after pressing the system start button on the touch screen. On the touch screen, only the basket feeding motor was on: the transverse conveyor motor and the basket unloading motor were not, indicating that there was no collection basket on the unloading basket conveyor belt at this time and that the basket feeding motor was conveying an empty basket to the unloading basket conveyor belt. At 26 s, on the touch screen, only the top photoelectric sensor 2 was not on: the top photoelectric sensor 1 and the bottom photoelectric sensor were on and the pressure sensor value was shown as 1.38488 kg. Only the transverse conveyor motor lit up on the touch screen, the basket unloading motor and the basket feeding motor did not light up, indicating that the leafy vegetables temporarily stored in the transverse conveyor belt started to fall into the collection basket at this time and had not yet reached the expected capacity of the collection basket. At 43 s, the bottom photoelectric sensor and top photoelectric sensors 1 and 2 were lit on the touch screen and the pressure sensor value was shown as 2.37229 kg. On the touch screen, only the basket unloading motor lit up: the transverse conveyor motor and the basket feeding motor were not lit up, indicating that the collection basket capacity had reached the expected capacity at this time and the unloading was in progress. At 83 s, the bottom photoelectric sensor and top photoelectric sensors 1 and 2 were not lit on the touch screen and the pressure sensor value was displayed as −0.0040102 kg. On the touch screen, only the basket feeding motor lit up: the transverse conveyor motor and the basket unloading motor did not light up, indicating that the collection basket with the expected capacity had been unloaded to the ground, and the basket feeding motor was transporting empty baskets to the basket unloading conveyor belt. Through bench simulation tests, it was determined that the control system for the automatic unloading and replenishment of baskets based on the cooperative detection control strategy of the photoelectric sensor and pressure sensor reduced the probability of misjudgment and misoperation and improved system performance. This was conducted with the probability of system misjudgment and misoperation serving as the main evaluation index. The simulation results demonstrated that the control system for the automatic unloading and replenishment of baskets based on a photoelectric sensor and pressure sensor cooperative detection control strategy could be error-free judgment and avoid misoperation, effectively improving the stability, accuracy, and rapidity of the system. The study’s findings could suggest a strategy to lessen the workload of operators and increase the operational effectiveness of harvesters for leafy vegetables.