Original Articles Open access

Energy optimization control of extended-range hybrid combine harvesters based on quasi-cycle power demand estimation

Authors

Published
14 July 2025
Section
Original Articles

Abstract

This study develops an energy management strategy (EMS) for hybrid combine harvesters to address fluctuating power demands in agricultural operations. By segmenting harvesting processes into quasi-periodic cycles linked to machine dynamics, the method integrates component-specific power models (header, conveyor, drum) for accurate energy estimation. Real-time feed rate adjustments are achieved through dynamic responses of critical components, optimizing cycle duration and power allocation. A genetic algorithm synchronizes energy distribution and cycle timing to minimize fuel consumption. Validated via AMESim/Simulink co-simulation with dual engine models, the strategy reduces fuel use by 21.1% compared to conventional systems. Key innovations include quasi-periodic load segmentation, component-response-based feed rate prediction, and GA-driven multi-objective optimization. The approach enhances adaptability to variable harvesting conditions, offering a scalable framework for energy-efficient electrification in agriculture. Results demonstrate significant potential for hybrid systems in reducing operational costs and emissions while maintaining productivity under dynamic workloads.

References

  1. Ali, A.M., Moulik, B., 2022. On the role of intelligent power management strategies for electrified vehicles: a review of predictive and cognitive methods. IEEE Trans. Transp. Electr. 8:368-383. DOI: https://doi.org/10.1109/TTE.2021.3115985
  2. Chai, X., Hu, J., Ma, T., Liu, P., Shi, M., Zhu, L., Zhang, M., Xu, L., 2024. Construction and characteristic analysis of dynamic stress coupling simulation models for the attitude-adjustable chassis of a combine harvester. Agronomy (Basel) 14:1874. DOI: https://doi.org/10.3390/agronomy14081874
  3. Chen, J., Ning, X., Li, Y., Yang, G., Wu, P., Chen, S., 2017. A fuzzy control strategy for the forward speed of a combine harvester based on KDD. Appl. Eng. Agr. 33:15-22. DOI: https://doi.org/10.13031/aea.11299
  4. Chen, J., Wang, Yifan, Wang, X., Wang, Yuehong, Hu, R., 2017. Development and application of remote video monitoring system for combine harvester based on embedded Linux. Proc. SPIE 10322. 17th Int. Conf. Electron. Inform. Eng. 1032223. DOI: https://doi.org/10.1117/12.2265530
  5. Deng, X., Yan, Z., Xu, D., Qi, Y., 2020. Land registration, adjustment experience, and agricultural machinery adoption: empirical analysis from rural China. Land (Basel) 9:89. DOI: https://doi.org/10.3390/land9030089
  6. Guo, J., He, H., Sun, C., 2019. ARIMA-based road gradient and vehicle velocity prediction for hybrid electric vehicle energy management. IEEE Trans. Veh. Technol. 68:5309-5320. DOI: https://doi.org/10.1109/TVT.2019.2912893
  7. Hu, J., Zong, C., Shi, M., Wang, L., Bi, Q., Xu, L., 2024. A robust ensemble surrogate model and its application in the in situ data modelling and analysis of a combine harvester. Engin. Optim. 56:1929-1949. DOI: https://doi.org/10.1080/0305215X.2023.2286509
  8. Kotenko, V., 2022. Method and results of the most efficient means of transport selection for executing orders of the grain crops delivery. Proc. Int. Conf. Transbaltica Transportation Science and Technology. Springer, pp. 606-617. DOI: https://doi.org/10.1007/978-3-031-25863-3_58
  9. Lang, J., Tian, J., Zhou, Y., Li, K., Chen, D., Huang, Q., et al., 2018. A high temporal-spatial resolution air pollutant emission inventory for agricultural machinery in China. J. Cleaner Prod. 183:1110-1121. DOI: https://doi.org/10.1016/j.jclepro.2018.02.120
  10. Liang, Z., Qin, Y., Su, Z., 2024. Establishment of a feeding rate prediction model for combine harvesters. Agriculture (Basel) 14:589. DOI: https://doi.org/10.3390/agriculture14040589
  11. Lipowski, A., Lipowska, D., 2012. Roulette-wheel selection via stochastic acceptance. Physica A 391:2193-2196. DOI: https://doi.org/10.1016/j.physa.2011.12.004
  12. Liu, T., Tan, W., Tang, X., Zhang, J., Xing, Y., Cao, D., 2021. Driving conditions-driven energy management strategies for hybrid electric vehicles: A review. Renew. Sust. Energ. Rev. 151:111521. DOI: https://doi.org/10.1016/j.rser.2021.111521
  13. Lu, E., Xu, L., Li, Y., Tang, Z., Ma, Z., 2020. Modeling of working environment and coverage path planning method of combine harvesters. Int. J. Agric. Biol. Eng. 13:132-137. DOI: https://doi.org/10.25165/j.ijabe.20201302.5210
  14. Luo, Y., Wei, L., Xu, L., Zhang, Q., Liu, J., Cai, Q., Zhang, W., 2022. Stereo-vision-based multi-crop harvesting edge detection for precise automatic steering of combine harvester. Biosyst. Engin. 215:115-128. DOI: https://doi.org/10.1016/j.biosystemseng.2021.12.016
  15. Savickas, D., Steponavičius, D., Kliopova, I., Saldukaitė, L., 2020. Combine harvester fuel consumption and air pollution reduction. Water Air Soil Pollut. 231:95. DOI: https://doi.org/10.1007/s11270-020-4466-5
  16. Schmid, R., Bürger, J., Bajcinca, N., 2019. A comparison of PMP-based energy management strategies for plug-in-hybrid electric vehicles. IFAC Papersonline 52:592-597. DOI: https://doi.org/10.1016/j.ifacol.2019.09.094
  17. Shi, D., Guo, J., Liu, K., Cai, Q., Wang, Z., Qu, X., 2023. Research on an improved rule-based energy management strategy enlightened by the DP optimization results. Sustainability (Basel) 15:10472. DOI: https://doi.org/10.3390/su151310472
  18. Shi, D., Liu, S., Cai, Y., Wang, S., Li, H., Chen, L., 2021. Pontryagin’s minimum principle based fuzzy adaptive energy management for hybrid electric vehicle using real-time traffic information. Appl. Energ. 286:116467. DOI: https://doi.org/10.1016/j.apenergy.2021.116467
  19. Shi, D., Pisu, P., Chen, L., Wang, S., Wang, R., 2016. Control design and fuel economy investigation of power split HEV with energy regeneration of suspension. Appl. Energ. 182:576-589. DOI: https://doi.org/10.1016/j.apenergy.2016.08.034
  20. Sun, L., Liu, M., Wang, Z., Wang, C., Luo, F., 2023. Research on load spectrum reconstruction method of exhaust system mounting bracket of a hybrid tractor based on MOPSO-wavelet decomposition technique. Agriculture (Basel) 13:1919. DOI: https://doi.org/10.3390/agriculture13101919
  21. Sun, Y., Liu, R., Zhang, M., Li, M., Zhang, Z., Li, H., 2022. Design of feed rate monitoring system and estimation method for yield distribution information on combine harvester. Compute. Electron. Agr. 201:107322. DOI: https://doi.org/10.1016/j.compag.2022.107322
  22. Wang, C., Huang, B., Xu, W., 2018. An integrated energy management strategy with parameter match method for plug-in hybrid electric vehicles. IEEE Access 6:62204-62214. DOI: https://doi.org/10.1109/ACCESS.2018.2876095
  23. Wang, S., Zhang, S., Shi, D., Sun, X., Yang, T., 2021. Research on hybrid modeling and predictive energy management for power split hybrid electric vehicle. Bull. Pol. Acad. Sci. 69:e137064. DOI: https://doi.org/10.24425/bpasts.2021.137064
  24. Wang, Y., Li, K., Zeng, X., Gao, B., Hong, J., 2023. Investigation of novel intelligent energy management strategies for connected HEB considering global planning of fixed-route information. Energy 263:125744. DOI: https://doi.org/10.1016/j.energy.2022.125744
  25. Xu, L., Li, Yang, Chai, X., Wang, G., Liang, Z., Li, Yaoming, Li, B., 2020. Numerical simulation of gas–solid two-phase flow to predict the cleaning performance of rice combine harvesters. Biosyst. Engin. 190:11–24. DOI: https://doi.org/10.1016/j.biosystemseng.2019.11.014
  26. Xuegeng, C., Haojun, W.E.N., Weirong, Z., Fochu, P.A.N., Yan, Z., 2020. Advances and progress of agricultural machinery and sensing technology fusion. Smart Agr. 2:16.
  27. Yang, T., Zhao, L., Li, W., Zomaya, A.Y., 2021. Dynamic energy dispatch strategy for integrated energy system based on improved deep reinforcement learning. Energy 235:121377. DOI: https://doi.org/10.1016/j.energy.2021.121377
  28. Yu, H., Kuang, M., McGee, R., 2013. Trip-oriented energy management control strategy for plug-in hybrid electric vehicles. IEEE Tr. Control Syst. Technol. 22:1323-1336. DOI: https://doi.org/10.1109/TCST.2013.2278684
  29. Yun, Q., Dean, Z., Wei, J., 2010. Combines speed servocontrol based on gray generalized predictive algorithm. Proc. IEEE Int. Conf. on Computer, Mechatronics, Control and Electronic Engineering. pp. 21-24.
  30. Zhang, F., Hu, X., Langari, R., Cao, D., 2019. Energy management strategies of connected HEVs and PHEVs: Recent progress and outlook. Prog. Energ. Combust. 73:235-256. DOI: https://doi.org/10.1016/j.pecs.2019.04.002
  31. Zhu, D., Pritchard, E., Dadam, S., Kumar, V., Xu, Y., 2021. Optimization of rule-based energy management strategies for hybrid vehicles using dynamic programming. Combust. Engin. 184:3-10. DOI: https://doi.org/10.19206/CE-131967
  32. Zhu, Z., Chai, X., Xu, L., Quan, L., Yuan, C., Tian, S., 2023. Design and performance of a distributed electric drive system for a series hybrid electric combine harvester. Biosyst. Engin. 236:160–174. DOI: https://doi.org/10.1016/j.biosystemseng.2023.10.015
  33. Zhu, Z., Zeng, L., Chen, L., Zou, R., Cai, Y., 2022. Fuzzy adaptive energy management strategy for a hybrid agricultural tractor equipped with HMCVT. Agriculture (Basel) 12:1986. DOI: https://doi.org/10.3390/agriculture12121986

Metrics

Citations and online attention from Dimensions, Altmetric and PlumX.