Modelling and optimization of operating parameters of an electronic cell type metering mechanism for urea super granules (USG) using EDEM-RSM approach

The development of an efficient electronic metering system is crucial for the successful deployment of urea super granules (USGs) in agricultural fields. Key parameters influencing the performance of the cell-type metering system for USG application include cell area, peripheral speed of the cell, and the level of hopper filling. Simulation of the metering system operation was conducted using EDEM, with a focus on optimizing input parameters to achieve 100% cell fill, maximum qualified rate for single cells, and minimization of missing or multiple cells. An electronic metering system was implemented in a soil bin, employing a Nema 23 stepper motor to control the peripheral speed of the cell. The synchronization with the transplanter was ensured through a rotary encoder, and various cell sizes were achieved using 3D printing. Using the EDEM-RSM approach, the optimal operating conditions based on the soil bin study were found as cell area of 1088 mm2, a metering roller peripheral speed of 0.24 m/s, and a 75% hopper fill. Under these conditions, the system demonstrated a 97% cell fill, a 91% qualified rate for single cells, with only 3.2% missing cells and 4.5% multiple cells. Quality class of metering was found as good based on indices such as missing index, multiple index, and quality of feed index, which were found as 3.2%, 4.5%, and 92.3%, respectively. The study demonstrated the robust predictive capability of the EDEM-RSM model in evaluating the performance of the cell-type metering system. These findings offer valuable insights for researchers and manufacturers seeking to optimize the development of automated ultrasonic (USG) applicators.