Management of mechanized harvesting through operational modeling<sup/>

Dias Neto, Américo Ferraz; Albiero, Daniel; Rossetto, Raffaella; Biagi, João Domingos

doi:10.5935/1806-6690.20230011

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Scientific Article • Rev. Ciênc. Agron. 54 • 2023 • https://doi.org/10.5935/1806-6690.20230011 copy

Management of mechanized harvesting through operational modeling¹ 1 Part of the first author's Thesis, presented to the Postgraduate Course in Agricultural Engineering, State University of Campinas (UNICAMP)

Gestão da colheita mecanizada por meio de modelagem operacional

Authorship SCIMAGO INSTITUTIONS RANKINGS

ABSTRACT

The activity of agricultural experimentation may require high budget and long periods of time for obtaining data. Due to production features, decision-making processes within agro-industrial mills that use sugarcane as raw material must be optimized. In this scenario, modeling operating systems that use embedded technology as agricultural automation enables the optimization of decision-making and influences operational performance and costs. This article presents a model for receiving and processing sugarcane based on its harvesting capacity, considering the harvestability index and the nominal capacity of the harvester. Sensitivity analysis enables the assessment of potential offenders and the reallocation of assets, thus optimizing resources and ensuring plant operation. This analysis also enables new possibilities, such as harvesting under different row spacings and harvesting simultaneously different rows.

Key words
Sugarcane harvest and loading; Modeling; Agricultural automation.

Parameter	Evaluation criteria
Agricultural productivity	t ha^-1
Trace length	Distance traveled by the harvester without the need for maneuvers, expressed in linear meters
Terrain slope	expressed in slope percentage
Occurrence of stones and stumps	Visual or area history assessment
Occurrence of erosion	Visual or area history assessment
Occurrence of weeds	Visual or area history assessment
Terrain leveling	Visual or area history assessment
Cane lodging	Visual evaluation

Parameter	Observation	Score	Maximum speed km h^-1
Slope	Up to 8%	1	6.0
	Up to 12%	2	5.0
	Up to 14%	3	3.0
	Over 14%	4	2.5
Occurrence of stones and stumps	No occurrence	1	6.0
	Some occurrence	2	5.0
	High occurrence	3	3.0
	Severe occurrence	4	2.5
Occurrence of erosion	No occurrence	1	6.0
	Some occurrence	2	5.0
	High occurrence	3	3.0
	Severe occurrence	4	2.5

Parameter	Observation	Score	Impact on operational capacity
Occurrence of weeds	No infestation	1	No impact
	Some infestation	2	10.0%
	High infestation	3	30.0%
	Severe infestation	4	50.0%
Terrain leveling	Leveled	1	No impact
	Somewhat leveled	2	2.5%
	Unleveled	3	7.5%
Cane lodging	Upright	1	No impact
	Some lodged stalks	2	5.0%
	Most of the stalks lodged	3	50.0%
	All of the stalks lodged	4	70.0%

Variable	Acronym	Unit
Financial assumptions
Opportunity cost	OC	% year
Fuel	Vfuel	R$ l^-1
Lubricants	Vlub	R$ l^-1
Equipment initial value	EIV	R$
Equipment lifespan	ELS	Years
Equipment residual value	ERV	%
Fill-ins	F	%
Absenteeism	A	%
Social charges	Soc	%
Wage	W	R$ month^-1
Implement initial value	IIV	R$
Implement lifespan	ILS	Years
Implement residual value	IRV	%
Operational consumption
Fuel	Fuel	l h^-1
Lubricant	Lub	l h^-1
Implement lubricant	Lub_imp	l h^-1
Maintenance	Mai	% EIV
Implement maintenance	Mai_imp	% IIV
Operational assumptions
Field productivity (according to tons of sugarcane per hectare)	TCH	t ha^-1
Trace length	TL	M
Spacing between rows	Sp	M
Rows harvested simultaneously	NL	amount
Corrected harvestability index	CHI	%
Nominal yield	NY	t h^-1
Harvester maximum speed	Vmax	km h^-1
Loading Capacity	Cload	T
Logistic times
End-of-row maneuver	MT	seconds.maneuver^-1
Auxiliary maneuver	Maux	min day^-1
Refuelling displacement	Dref	min day^-1
Nonproductive hours	Hnon	min day^-1
Work shifts	WS	shifts.day^-1
Meal breaks	MS	min shift^-1
Shift change	SC	min shift^-1
Area change	AC	min day^-1
Empty displacement	Demp	Min
Loaded displacement	D_load	Min
Load transfer	T_load	Min
Maintenance times
Interval between field maintenance	IFM	h
Duration of field maintenance	DFM	Min
Interval of garage maintenance	IGM	h
Duration of garage maintenance	DGM	Min
Operational supply times
Refueling interval	RI	h
Refueling duration	Dref	Min
Interval between lubrication	Ilub	h
Lubrication duration	Dlub	Min
Knife exchange interval	Ikni	h day^-1
Knife exchange duration	Dkni	min change^-1
Equipment cleaning	Ceq	min day^-1
Checklist	Check	min day^-1

Variable	Unit	Cut	Load
Opportunity cost (OC)	% year	8.50%
Fuel value (Vcomb)	R$ l^-1	2.90
Lubricating value (Vlub)	R$ l^-1	12.70
Equipment initial value (EIV)	R$	1,050,000	438,600
Equipment lifespan (ELS)	years	7	10
Equipment residual value (ERL)	%	25%	20%
Fill-ins (F)	%	16.7%	16.7%
Absenteeism (A)	%	1.5%	1.5%
Social charges (SC)	%	70.0%	70.0%
Wage (W)	R$ month^-1	2,200.00	2,000.00
Implement initial value (IIV)	R$		220,000
Implement lifespan (ILS)	years		10
Implement residual value (IRV)	%		10%

Variable	Unit	Cut	Load
Fuel (Fuel)	l h^-1	35.00	9.50
Lubricant (Lub)	l h^-1	0.10	0.15
Implement lubricant (Lub_imp)	l h^-1		0.05
Maintenance (Mai)	% EIV	30%	10%
Implement maintenance (Mai_imp)	% IIV		10%

Variable	Unit	Cut	Load
Field productivity (TCH)	t ha^-1	76.46
Trace length (TL)	m	500.00
Spacing between rows (SBR)	m	1.50
Rows harvested simultaneously (NL)	amount	1.00
Corrected harvestability index (CHI)	%	19%
Nominal yield (NY)	t h^-1	130.00
Harvester maximum speed (Vmax)	km h^-1	6.00
Loading Capacity (Cload)	t		19.00

Variable	Unit	Cut	Load
End-of-row maneuver (TM)	seconds.maneuver^-1	110
Auxiliary maneuver (Maux)	min day^-1	44.0
Refuelling displacement (Dref)	min day^-1	10.0
Nonproductive hours (Hnon)	min day^-1	110.0	15.0
Work shifts (WS)	shifts.day^-1	3	3
Meal breaks (MB)	min shift^-1	30.0	30.0
Shift change (SC)	min shift^-1	12.0	12.0
Area change (AC)	min day^-1	35.0	34.0
Empty displacement (Demp)	min		9.0
Loaded displacement (D_load)	min		8.0
Load transfer (T_load)	min		5.0

Variable	Unit	Cut	Load
Interval between field maintenance (IFM)	h	15.00	24.00
Duration of field maintenance (DFM)	min	110	100
Interval of garage maintenance (IGM)	h	900.0	230.00
Duration of garage maintenance (DGM)	min	1.500	1.110

Variable	Unit	Cut	Load
Refuelling interval (RI)	h	24.00	24.00
Refuelling displacement (Dref)	min	24.00	20.00
Interval between lubrication (Ilub)	h	24.00	24.00
Lubrication duration (Dlub)	min	10.00	30.00
Knife exchange interval (Ikni)	h day^-1	18.00
Knife exchange duration (Dkni)	min change^-1	30.00
Equipment cleaning (Ceq)	min day^-1	60.00	15.00
Checklist (Check)	min day^-1	21.00	21.00

Variable	Acronym	Unit	Formula	Equation
Results
Daily milling	M_day	t day^-1	$M_{day} = M_{hour} * 24$	1
Effective harvest days	EHD	Day	$E H D = H D * A A$	2
Corrected yield	HCY	t h^-1	$H C Y = {\begin{matrix} N Y * (1 - I C), I C < 70 % \\ N Y * 30 %, I C \geq 70 % \end{matrix}}$	3
Harvest logistics time	T_logh	h day^-1	$T_{\log h} = W S * (\frac{M S + S C}{60}) + \frac{M A}{60}$	4
Logistic loading time	T_logt	h day^-1	$T_{\log t} = W S * (\frac{M S + S C}{60}) + \frac{M A + Hnon}{60}$	5
Field maintenance time	FMT	h day^-1	$F M T = \frac{24 * D F M}{60 * I F M}$	6
Garage maintenance time	GMT	h day^-1	$G M T = \frac{24 * D G M}{60 * I G M}$	7
Maintenance time	T_mai	h day^-1	$T_{m a i} = F T M + G M T$	8
Mechanical availability	Amec	%	$Amec = (1 - \frac{T_{mai}}{24}) * 100$	9
Refuelling time	T_ref	h day^-1	$T_{ref} = \frac{24 * Dref}{60 * R I}$	10
Lubrication time	T_lub	h day^-1	$T_{lub} = \frac{24 * I lub}{60 * D lub}$	11
Knife exchange time	T_kni	h day^-1	$T_{k n i} = \frac{24 * D k n i}{60 * I k n i}$	12
Harvester operational supply time	TOS_H	h day^-1	$T S O_{H} = T_{kin} + T_{lub} + T_{ref} + \frac{C e q + Check}{60}$	13
Loading operational supply time	TOS_L	h day^-1	$T S O_{L} = T_{lub} + T_{ref} + \frac{C e q + Check}{60}$	14
Harvester engine hours	HEH	h	$H E H = 24 - (T_{\log h} T_{m a i} + T O S)$	15
Loading engine hours	LEH	h	$L E L = 24 - (T_{\log t} + T_{m a i} + T O S_{t})$	16
Linear productivity	Plin	t m^-1	$P Pin = \frac{T C H * E s p}{10.000}$	17
Operating speed	Sop	km h^-1	$Sop = \frac{10.000}{1.000 * Plin * N L}$	18
Harvested volume per row	HVR	t	$H V R = P lin * N L * T L$	19
Time trace length + Maneuver	TTLM	min	$TTLM = \frac{(60 * T L)}{(1000 * Sop)} + \frac{M T}{60}$	20
Harvested rows	Rhar	harvested rows day^-1	$Rhar = \frac{H E H - \frac{Maux + Dref + Hnon}{60}}{N L}$	21
End-of-row maneuver time	T_erm	h day^-1	$T_{erm} = \frac{R h a r * M T}{3.600}$	22
Total maneuver time	MT_TOT	h day^-1	$M T_{tot} = T_{erm} + \frac{Maux + Dref + Hnon}{60}$	23
Loading distance	LD	M	$L D = \frac{Cload}{Plin * N L}$	24
Amount loading maneuvers	ALM	maneuver.load^-1	$A L M = 1 + (\frac{D C Y}{T L})$	25
Loading time	LT	Min	$L T = (\frac{\frac{L D}{1.000}}{S o p}) * 60 + \frac{A L M * M T}{60}$	26
Loading cycle total time	LCTT	Min	$L C T T = L C T T + D_{cmp} + D_{load} + T_{load}$	27
Loading cycles per day	LCD	cycles d^-1	$L C D = \frac{60 * L E H}{L T C T}$	28
Harvester operational yield	HOY	t day^-1	$H O Y = (H E H - M T_{too}) * (1.000 * Sop * P lin * N L)$	29
Loading operational yield	LOY	t day^-1	$L O Y = C D * Cload$	30
Loading/harvester ratio	Ralh	Amount	$Ralh = \frac{M o r}{L o r}$	31
Harvester productive hours	HPH	h day^-1	$H P H = H E H - M T_{tot}$	32
Harvester use	Uh	h year^-1	$U H = E H D * H E H$	33
Loading use	Ul	h year^-1	$U l = E H D * L E H$	34
Total harvester fuel consumption	Hfuelt	l year^-1	$H f u e l t = U h * F u e l$	35
Total loading fuel consumption	Lfuelt	l year^-1	$Lfuelt = U i * F u e l$	36
Harvester ton fuel consumption	Hfuel	l t^-1	$H f u e l = \frac{H f u e l}{H O Y * E H D}$	37
Loading ton fuel consumption	Lfuel	l t^-1	$Lfuel = \frac{L f u e l}{L O Y * E H D}$	38
Total harvester lubricant consumption	Hclubt	l year^-1	$Hclubt = U h * L u b$	39
Total loading lubricant consumption	Lclubt	l year^-1	$Lclub t = U i * L u b$	40
Total loading implement lubricant consumption	Liclubt	l year^-1	$Lic lub = U h * L u b$	41
Harvester ton lubricant consumption	Hclub	l t^-1	$Hclub = \frac{H c lub t}{H O Y * E H D}$	42
Loading lubricant consumption	Lclub	l t^-1	$Lc lub = \frac{L c l u b t + L i c l u b t}{L O Y * E H D}$	43
Harvester 24-hour effective yield	HDEY	t h^-1	$H D E Y = \frac{H O Y}{24}$	44
Harvester engine effective yield per hour	HEEY	t h^-1	$HEEY = \frac{H O Y}{H E H}$	45
Harvester effective yield per productive hour	HPEY	t h^-1	$H P E Y = \frac{H O Y}{H P H}$	46
Loading effective yield per productive hour	LPEY	t h^-1	$LPEY = \frac{LOY}{24}$	47
Harvester fuel cost	Hfuelcost	R$ h^-1	$Hfuel cost = HEEY * Hfuel * Vfuel$	48
Loading fuel cost	Lfuelcost	R$ h^-1	$Lfuel cos t = L P E Y * L f u e l * V f u e l$	49
Harvester lubricant cost	Hlubcost	R$ h^-1	$Ccustlub = RECM * Hclub*V lub$	50
Loading lubricant cost	Llubcost	R$ h^-1	$Llubcos t = R E T * L c lub * V lub$	51
Harvester maintenance cost	Hmaicost	R$ h^-1	$Hmai \cos t = \frac{E I V * M a i}{U h}$	52
Loading maintenance cost	Lmaicost	R$ h^-1	$Lmai \cos t = \frac{E I V * M a i}{U i}$	53
Loading implement maintenance cost	Limaicost	R$ h^-1	$Limai \cos t = \frac{E I V * M a i_{inp}}{U i}$	54
Harvester operators cost	Hopercost	R$ h^-1	$Hopercost = \frac{W * (1 + Soc) * 13 * W S * (1 + A) * (1 + F)}{U h}$	55
Loading operators cost	Lopercost	R$ h^-1	$Loper cost = \frac{W * (1 + Soc) * 13 * W S * (1 + A) * (1 + F)}{W i}$	56
Harvester depreciation	Depreh	R$ h^-1	$\begin{aligned} {[E I V - \frac{E I V * E R V}{(1 + O C)^{E L S}}] * [\frac{(1 + O C)^{E L S} * O C}{(1 + O C)^{E L S} - 1}]} + \\ Depreh = & \frac{+ {[V I I - \frac{I I V * I R V}{(1 + O C)^{I L S}}] * [\frac{(1 + O C)^{I L S} * O C}{(1 + O C)^{I L S} - 1}]}}{U h} \end{aligned}$	57
Loading depreciation	Deprel	R$ h^-1	$\begin{array}{r} Deprel = \frac{{[E I V - \frac{E I V * E R V}{(1 + T O)^{E L S}}] * [\frac{(1 + O C)^{E L S} * O C}{(1 + O C)^{E L S} - 1}]} + {[V I I - \frac{I I V * I R V}{(1 + O C)^{I L S}}] * [\frac{(1 + O C)^{I L S} * O C}{(1 + O C)^{I L S} - 1}]}}{U i} \end{array}$	58
Harvester total cost	Htotcost	R$ h^-1	$\begin{matrix} H t o t \cos t = H f u e l \cos t + H l u b \cos t + H m a i \cos t + H o p e r \cos t + D e p r e h \end{matrix}$	59
Loading total cost	Ltotcost	R$ h^-1	$\begin{matrix} L t o t \cos t = L f u e l \cos t + L l u b \cos t + L m a i \cos t + L o p e r \cos t + D e p r e l \end{matrix}$	60
No-stop tractor truck total cost	Nstrutotcost	R$ h^-1	$\begin{matrix} N s t r u t o t \cos t = N s t f u e l \cos t + N s t l u b \cos t + N s t m a i c o s t + N s t o p e r \cos t + N s t d e p r e c c o s t \end{matrix}$	61
Harvester ton total cost	Costharvest	R$.t^-1	$Costharvest = \frac{Htot \cos t}{HEEY}$	62
Loading ton total cost	Costload	R$.t^-1	$Cosload = \frac{TLtot \cos t}{RETD}$	63
Harvesters needs	Nhar	amount	$Nhar = \frac{M_{d a y}}{HOY}$	64
Loading needs	Nload	amount	$Nload = Nhar * Ralh$	65

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[1] Editor-in-Article: Prof. Alek Sandro Dutra - alekdutra@ufc.br

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Management of mechanized harvesting through operational modeling1 1 Part of the first author's Thesis, presented to the Postgraduate Course in Agricultural Engineering, State University of Campinas (UNICAMP)

Gestão da colheita mecanizada por meio de modelagem operacional

ABSTRACT

Management of mechanized harvesting through operational modeling¹ 1 Part of the first author's Thesis, presented to the Postgraduate Course in Agricultural Engineering, State University of Campinas (UNICAMP)