Automatic Control System for Maize Threshing Concave Clearance Based on Entrainment Loss Monitoring

Complex harvesting environments and varying crop conditions often lead to threshing cylinder blockage and increased entrainment loss in maize grain harvesters. To address these issues, an electric-driven automatic control system for maize threshing concave clearance based on real-time entrainment loss monitoring was developed. The system automatically adjusts concave clearance parameters at different harvesting speeds to maintain grain entrainment loss within an optimal range. First, an adjustable concave structure based on a crank-link mechanism was designed, with a threshing clearance adjustment range of 15–47 mm and motor rotation angle of 0–48°. Subsequently, an EDEM simulation model of the mixed material discharge inside the threshing cylinder was established to determine the optimal installation position of the entrainment loss monitoring sensor based on piezoelectric ceramic-sensitive elements. The sensor was positioned at the left tail end of the concave sieve, with a minimum distance of 58 mm between the sensitive plate centerline and threshing concave sieve and an installation angle of 65° relative to the horizontal plane. A maize threshing clearance control method based on fuzzy neural network PID control algorithm was proposed, and Simulink simulation optimization verified its superior performance with fast response speed. After system integration, field trials were conducted at low, medium, and high operating speeds with preset ideal entrainment loss intervals. The results showed that control was unnecessary at low speed, the control system-maintained entrainment loss within set range at medium speed, and maximum threshing clearance was needed at high speed. Finally, comparative trials of threshing performance with and without the control system were conducted at medium harvesting speed. Results showed that the entrainment loss rate decreased by 43.75% with the control system activated, significantly reducing maize threshing entrainment losses. This study overcame the barrier of maize threshing parameter adjustment being heavily reliant on manual experience and provided theoretical support for the intelligent grain harvesting equipment.