Development and Testing of a Tiered Differential Apparatus for Smart Assessment of Impurity Rate in Mechanically Collected Sugarcane

China is the world’s third-largest sugarcane producer. When mechanically harvested sugarcane enters the sugar mill, impurity rate detection is required. However, due to the piling up of sugarcane, significant errors may occur in the detection results. Therefore, this research addresses the issue of low accuracy in machine vision detection due to the dense stacking of sugarcane. An innovative graded device was developed, featuring a three-stage progressive geometric constraint system with roller-belt gaps of 100 mm, 45 mm, and 33 mm, alongside differential traction with speed ratios of 3:1, 4:1, and 5:1. Utilizing the normal distribution characteristic for the diameter of 500 sugarcane stalks, the gap parameters were refined through a dynamic stiffness model. Through power validation and multi-factor orthogonal experiments, the study uncovered the interactive influences of sugarcane weight, primary conveyor belt speed, and speed ratio on the single-layer rate and area ratio. Our findings indicate that sugarcane weight is the primary determinant of the material’s single-layer rate, while the speed ratio is crucial for managing sugarcane distribution density, more so than the primary conveyor belt speed. Notably, increasing the speed ratio from 3:1 to 5:1 results in a decrease in area ratio from 26.8% to 22.0%. After utilizing the graded differential device, the average accuracy of machine vision detection achieved 94.90%, with only two misidentifications on average. In comparison to the control group, detection accuracy improved by 26.93%, misidentifications dropped by about 81.80%, and detection speed was recorded at 55.5 ms. These outcomes confirm that the device not only enhances detection accuracy but also significantly lowers the misidentification rate, thereby creating a stable, clear, and efficient detection environment.