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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
Ensures the work space
Achieves a full cutting process
Ensures the speed detection
Ensures the working accuracy
Ensures the cutting accuracy
Achieves a full cutting process
Ensures the cutting speed
Removes the branches
Ensures the work space
Easy to handle
Low noise
Ensures a healthy work environment
Ensures a secure work environment
Ensures the working accuracy
Rhythmicity of the process
Ensures the work space
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 (€)
PM
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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
Actual delivery date: 23.06.2014
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
PM
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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
Personnel Costs (€) Subcontract
Consumables,
Equipment
and Prototype
Travel &
SubsistenceTotal direct costs Overheads Total costs (€)
33
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
Actual delivery date: 30.09.2014
Planned delivery date: September
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D 5.09 Evaluation of the prototype performance
D 5.10 Report on training activities and business analysis
2014
Actual delivery date: 30.09.2014
Planned delivery date: September
2014
Actual delivery date: 30.09.2014
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
Personnel Costs (€) Subcontract
Consumables,
Equipment
and Prototype
Travel &
SubsistenceOverheads Total costs (€)
37
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
Submission date: 30.09.2013
Expected: September 2014
Submission date: 30.09.2013
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 &
SubsistenceTotal direct costs Overheads Total costs (€)
PM