Structural optimization and performance evaluation of a sugarcane leaf mulching machine

Existing sugarcane leaf mulching machines struggle to process high-fiber, tough sugarcane leaves, leading to incomplete mulching and uneven residue distribution. These limitations hinder subsequent farming operations and increase energy consumption. To address these challenges, this study presents a structural optimization and performance analysis of the 1GYF-150 sugarcane leaf mulching machine, introducing an enhanced, high-efficiency mulching mechanism. The operational principles of the machine were analyzed, and the effects of different blade types, including straight and hammer-shaped blades, on mulching performance were evaluated. Key parameters—such as blade structure, rotational speed, and arrangement—were optimized to improve mulching quality and pick-up efficiency. Further, a balance analysis of the cutter roller was conducted, incorporating MATLAB optimization algorithms and a fuzzy reliability function to enhance the roller’s structural integrity and reduce weight. Field tests under typical post-harvest conditions (leaf moisture content of 31.8 %, representing the average humidity of sugarcane leaves in tropical regions) demonstrated that the optimized machine achieved a pick-up rate of 98.4 % and a mulching rate of 94.4 % (≤20 cm), reflecting improvements of 0.8 % and 7.1 % over the previous design, respectively. This study provides a valuable reference for advancing sugarcane leaf mulching machine performance and offers insights into more effective utilization of sugarcane leaf resources.