Exclusive Imperador 3.0 Test Drive

Equipped with a pneumatic system, Stara's Imperador 3.0 is a machine that can carry out spraying, distribution of solid products and seed sowing operations.

For readers of the March edition, which runs parallel to Expodireto 2019, in the city of Não-Me-Toque in Rio Grande do Sul, Revista Cultivar Máquinas presents a test with a truly innovative machine. This is Stara's Imperador 3.0, a piece of equipment that has a triple function, making it a very versatile machine that can be used in various operations during the harvest.

In 2016, the company launched this equipment, enabling the spraying and distribution of solid products. In 2018 it added an additional function, with the possibility of sowing plant seeds that can serve as cover after harvest. This new equipment features a seeding device that uses a pneumatic seed driving and distribution system. This system came to be known as Ponte Verde. In addition to being purchased with the new machine, it can be mounted on equipment that has been purchased in the basic configuration. Therefore, the great advantage is that the farmer who has the product purchased before the launch of Ponte Verde can purchase this equipment as an option and assemble it without problems, as one of the

The difference that makes this possible is that the controller that acts on the Ponte Verde is the same one used for the sprayer and the solid product distributor, with a disc.

It is almost unnecessary to defend the establishment of practices that enable permanent vegetation cover of the soil. The Southern states have established a culture of soil conservation, in which permanent cover is a key factor for success and obtaining high productivity. In the South, in general, oats, vetch or even mixtures of crop seeds, and in the Central-West, mainly brachiaria. There is no longer any way to think about a balanced system between production and conservation, without a culture protecting the soil.

There are several ways to introduce one culture following another. However, if it is possible to sow the cover crop in advance, when the main crop is still in the field, it represents a fundamental saving of time. It is natural to understand that the protective capacity of a young plant is lower than that of an already established one. Therefore, it is necessary to intersperse sowing before harvesting, and it is essential to define the stage of the main crop for this sowing. The most appropriate application time seems to be the beginning of senescence, when defoliation begins, in the case of soybeans, our main national crop.

Although there is a lot of data and information from research bodies, Stara has established partnerships for tests, most of them on commercial crops in the states of Rio Grande do Sul and Paraná. It is known that soybeans at the end of the cycle generate little coverage, so advancing the sowing process of a winter crop ensures that there is coverage at harvest. Parallel to the theme of inserting cover crops, this equipment also provides rural producers with the possibility of working with fractional application of solid products, when convenient, technically recommended and economically viable.

Our main focus in this test is this pneumatic seed distribution equipment, but we will also evaluate its integration into a single machine for spraying and distributing solid products. Nowadays, the sprayer has already taken a leading role in modern agricultural production processes, being one of the most used machines in the cycle, made up of different phases. When a machine adds, in addition to the sprayer, a distributor, its use increases significantly. Even introducing the sowing function, it is necessary to understand that its use on a rural property will be even more intense.

It should be noted that the position of the central spray bar and consequently the liquid deposit is an important factor for the possibility of placing the solids and seed deposit at the rear of the structure. The spray bar, in this new project, now includes, in addition to the nozzles, dispersers that provide seed distribution.

ENGINE AND TRANSMISSION

The Imperador 3.0 is equipped with a Cummins engine, with six cylinders in line, turbocharged, which provides 223 hp of maximum power. This is mounted transversely on the machine chassis and is located just behind the cab. The engine has electronic management that complies with current emissions control legislation, Proconve MAR-I. Stara technicians reported that the company strengthened relations with the engine supplier, which obtained the best engine performance map, which resulted in the possibility of providing users with an economical mode (ECO) function. The engine's optimal operating range is close to 1.800 rpm, which increases fuel economy. This function is available with a simple touch on the machine management system monitor.

The transmission system mounted on the machine has a hydraulic pump coupled to the engine and four wheel motors. The entire system is from the Rexroth brand, which belongs to the Bosch Group. The transmission is full 4x4 and has traction control, which, by reading the speed difference between the wheels, controls the oil flow, thus reducing slippage. The equipment has a ramp capacity of 31,7%, which is very interesting for crops in southern Brazil which, in general, have more undulating terrain. It is the wheel reducers that allow this range.

With four “gears” for moving the machine, it has maximum speeds of 16km/h, 22km/h, 25km/h and 42km/h, successively. The first three are indicated by the manufacturer as the working speeds, and the fourth is used only for transport. These gears can be selected while the equipment is in motion, using a switch located on the multifunction control.

The entire hydraulic system of the Imperador 3.0 uses 195 liters of integrated hydraulic oil, which must be changed every 1.000 hours. The oil supply is the result of a partnership between Stara and Iconic Lubrificantes (a joint venture created by Ipiranga and Chevron), which developed an exclusive specification 68 oil that can be purchased at Stara dealerships and resellers.

STRUCTURE AND DEPOSITS

The Imperador 3.0 is a self-propelled equipment that combines a sprayer with central bars, a distributor and a pneumatic seeder (optional). The basic structure is a chassis with longitudinal spars and cross members, where all components are added. The central position of the bars gives the machine stability by distributing its weight over operations. For distribution, the weight is divided 44% at the front and 56% at the rear. For spraying, the weight is equally divided, 50% front and 50% rear. This difference is due to the position of the deposit being used. The total mass of the Imperador 3.0, empty, is 9.980kg and 11.680kg (1.700kg more) when equipped with the Up and Down system.

Unlike the Imperador 3000 and 4000 self-propelled sprayers, the Imperador 3.0 has a steering system only on the front wheels of the machine. The machine is equipped with an active pneumatic suspension system, with a three-point system, 20cm travel and four independent air pockets, which provide better adaptation to the terrain, lower slippage and improved application quality.

SPRAYING, DISTRIBUTION AND SEEDING SYSTEMS

The spraying system is based on a stainless steel centrifugal pump with a flow rate of 430 liters/minute. The piping, also made of stainless steel, guarantees greater durability of the components due to corrosion resistance. The application bar, which can be 27m or 30m, is divided into seven sections, one central and three on each side, and can be automatically turned off to avoid overlapping (for spraying), when the vehicle passes over an applied area and which has been registered by the system. The bars are fixed to the central frame by four points and have an exclusive stability control, fitted to the entire Imperador line. The bars are damped using gas-filled hydraulic accumulators.

The body of the spray nozzles is triple, which allows the assembly of three spray tips that can be selected just by turning the rosette on the body. The Imperador 3.0 has a calibrated return, a system that prevents the nozzles from overloading, as in the case of a section being turned off. In this case, instead of the syrup remaining in the pipe or being distributed between the open nozzles, it returns to the reservoir. This ensures that the working pressure is constant in the system.

The syrup incorporator, located to the left of the machine, is easy for the operator to access, with a capacity of 35 liters and a system for washing product packaging. This process has a clean water reservoir with a capacity of 240 liters, providing good autonomy to carry out the triple wash. The Imperador has a self-refueling system, optional on the basic model, which has a maximum flow of 800 liters per minute. The filling set is mounted on the front right of the machine and is easily accessible to the operator.

The solid product distribution system has a stainless steel reservoir mounted on the rear of the machine, with a capacity of three cubic meters. A rubber mat is installed at the bottom of the reservoir to transport the product to the distribution discs. The two discs are driven through a transmission box, driven by a hydraulic motor.

At the end of the conveyor belt, a gate is installed to limit the quantity of product, with fixed adjustment, done manually. To establish the dose to be applied, the Topper 5500 controller performs this calibration, which modifies the speed of the belt to obtain the amount of product that will fall on the discs. The equipment also has a double gate system, which has its opening automatically and individually controlled for finishing and borders.

Access to the solids and seed reservoir is via a ladder located at the rear left of the machine. To close the reservoir, the user can optionally purchase a tarpaulin that allows for easy and quick closing, using a system of cables and cranks. To assist with the rear view of the machine and the application, a camera is installed and transmits images to the Topper 5500 monitor. Optionally, the Imperador 3.0 can use up to six cameras, a number supported by the Topper 5500.

In addition to the distribution of solids, the Imperador 3.0 has a pneumatic seeding system, where it is possible to distribute them along the entire length of the bar. Changing from one system to another is simple and is carried out by simply touching a switch located on the control panel, after dismantling the distributor disc system and assembling the pneumatic system.

The pneumatic seeding system has a turbine, which provides an air flow, two rotors placed below the dosing belt, to distribute it evenly to both sides, two seed mixers/separators and dispersers distributed on the spray bar. The reservoir for placing seeds is the same as that used for solids and the dose is also controlled through the speed of the rubber belt.

Thus, the belt doses the seeds, which go to the rotors that guarantee the uniform flow of the product. Afterwards, they are taken to the mixer, where they are distributed evenly to the ducts located in the bars until they reach the dispersers spaced at 0,95m (30m bars) and 1m (27m bars). Therefore, with this system it is possible to use the same spray trail to carry out seeding, reducing crushing and making it possible to carry out controlled traffic practices.

GAUGE ADJUSTMENT AND FREE SPAN

The Imperador 3.0 allows the gauge to be adjusted from 2,8m to 3,5m. This adjustment can be made by the operator, from the operating station, with a small movement of the vehicle. As for the free space, important for application in crops in advanced stages of development, this equipment can be adjusted to two heights, 1,43m and 1,83m. The system called “up and down” uses a set of levers and a hydraulic piston on each wheel, which, when activated from inside the cabin, causes an elevation of 40cm in the height of the equipment. This system, launched in 2107, is truly innovative and different from the solutions used by competitors. When activated, on the Topper 5500 monitor, it projects the equipment backwards and upwards, giving these two height options. Although optional in the basic models, the company states that most producers have chosen to purchase the machine with this device, as the ease of adjustment and usefulness are enormous.

CABINS

The Imperador 3.0 operator position was one of the positive surprises for the test team. Access to the cabin is via a staircase, which we were pleased with, as the first step is very close to the ground, making it easier to start the climb. This ladder is retractable and moves automatically depending on the vehicle's stopping conditions, which must have the manual brake activated for access and exit to be permitted. There are good handholds to help you climb up and provide support when descending. Internally, the cabin also made a positive impression, as it has a great finish and an adequate distribution of controls. As a central and multifunction control, there is a joystick, where the function of increasing speed in each gear is done by moving the control longitudinally. Gear changing is done simply by touching two switches positioned behind the lever, within reach of the index and middle fingers. The function of adjusting the height of the application bar is done with this command, with a touch of the thumb, as well as changing the monitor screens, positioned on the right, at eye level.

TOPPER, PILOT AND TELEMETRY TECHNOLOGY

The Imperador 3.0 is already factory equipped with the Topper 5500 controller, which is responsible for managing the machine and controlling spraying, distribution and seeding. Therefore, it is through the interface that the application and distribution rate can be configured. The monitor is located on the operator's right side and is easily accessible, and nine screens can be configured.

The controller can work with either a free or paid GPS signal (RTK antenna), therefore, two application modes are possible, with fixed rate and variable rate. In the fixed rate system, the operator informs the dose to be applied and it does not change. When using the variable rate, it is possible to change the dose as recommended through fertility and productivity maps.

Together with the Topper 5500, the assisted steering system or autopilot is installed, which is extremely important for improving the machine's operational efficiency, reducing failures and reducing dents. This allows work in curved mode and straight mode. Another technology used in Imperador 3.0 is the telemetry system, making it possible to monitor in real time the operation that the machine is performing and information about applications.

TEST

The Imperador 3.0 test was carried out in a Stara prototype and training test area, located at the factory headquarters in the municipality of Não-Me-Toque, in Rio Grande do Sul. During the test we had the opportunity to evaluate all devices that make up the machine, its applicability and functionality, in addition to the ergonomics provided when activating the controls.

The first part of the test consisted of a brief period of basic explanations of operation and adapting the control station for the operator's comfort by adjusting the steering column, which can be done in three parts: tilt, adjustment of angle and depth adjustment. Furthermore, the seat was adjusted, which has pneumatic suspension and button operation.

Basically, the main control of this self-propelled equipment is carried out through the joystick present on the console on the operator's right side, which defines the direction, travel speed, gear changes, bar height commands in relation to the crop. , activating spraying or distribution, changing the Topper 5500 screen and enabling/disabling the autopilot. We took the opportunity to test the sensitivity and ease of changing functions.

The Imperador 3.0 is equipped with several protection devices against incorrect use and operator safety. This way, basic errors and security problems are blocked by the system. The function of enabling the machine's bars was created due to the need for protection when handling the machine, if the operator presses one of the bar activation keys on the joystick. Every time the bar is required to be used and handled, an activation request appears on the Topper 5500 monitor so that they can be enabled and used.

Still on the bars, the Imperador 3.0 features electro-hydraulic drive controls for their correct use. The first is to activate the spray pump using the activation button. The second is to release the bar (frame) from the self-propelled vehicle chassis, so that it remains independent of it at the time of spraying. The third is the opening of the first part of the bars automatically, to the point predetermined by the factory, through sensors installed on the hydraulic pistons so that the bar is always in a transverse position in relation to the chassis. And the last command is to open the second part of the bar manually.

Another safety device present on the machine is the emergency button for the autopilot. This button is responsible for cutting off the power supply to the autopilot, to prevent its activation when the self-propelled vehicle is outside the work field.

The change of functions (spraying, distribution or Green Bridge) is also carried out using an electro-hydraulic drive. When selecting the function, screens change on the Topper 5500 monitor and it issues a warning to the operator. All Imperador 3.0 application and usage settings are defined through the Topper 5500, a platform developed in an Android environment, which allows customization of functions and commands, according to the operator's preference.

The second part of the test was the operation of the self-propelled vehicle on the prototype test track. Following the pre-established route, we observed the stability of the bars, the comfort of the cabin and the suitability of the sprayer to the terrain, with and without the Up and Down system activated.

We tested the 4x4 hydrostatic transmission with traction control on the ramp present on the track and observed the remarkable performance of the engine control modules, clearly hearing the rotation variation to adapt to the dynamic conditions.

The distribution and spraying test was also carried out, monitoring on the Topper 5500 monitor next to the console the displacement speed, the working gear, the speed (rotation) of the turbine, the product application/distribution rate and the deposit level. . In addition, it is possible to observe the areas where it has already been applied, the sections of the spray bar that are active or the distribution gates that are active.

FINAL CONSIDERATIONS

The team from the Agrotechnology Laboratory of the Agricultural Machinery Testing Center has been invited to several tests by Revista Cultivar. Each of them brings us positive surprises, whether due to innovation, the diversity of solutions and even the conditions of each location where this evaluation is conducted.

We evaluate the experience of testing this equipment as very positive, due to its variety of functions and versatility. However, the visit to the Stara environment was also positive, which has special characteristics, being a local company and with a production system in which the projects and the significant majority of components are manufactured autonomously. Almost all of the equipment we tested is assembled with parts manufactured by Stara, including the castings, which are produced at the Carazinho unit, a neighboring city of Não-Me-Toque.

What also caught our attention was the integration between the different sectors of the factory, such as the industrial and marketing part, where it is clear that the projects are developed and the components manufactured by people who live in the same environment. It is rare to find agricultural equipment manufacturing companies where the software and hardware are developed together with the engineering sectors. Perhaps this is one of the secrets to the success of this company that is growing and making an entire region proud.

As for the equipment tested, we see that this option of using a self-propelled vehicle for spraying and distribution is an excellent alternative to the damage caused by the crushing of crops in advanced stages of development. It seemed clear to us that the option of equipment that performs several functions is not particularly suitable for large producers in the states of the Central-West of the country, but that it fits perfectly in the cases of those producers with an intermediate area size, perhaps between 300 and 1.000 hectares.

Ultimately, this self-propelled vehicle that combines three different functions will certainly have great acceptance in the Brazilian market, due to the benefits it provides by enabling producers to use a single machine in different activities. But, apparently, one of the biggest differences is the pneumatic distribution system, called Ponte Verde, which meets a strong tendency in Brazilian crops to anticipate the sowing of green covers, reducing the windows between harvests.

 Stara

Founded in 1960, Stara is an agricultural company that operates throughout the national territory, and is present worldwide on five continents, exporting its products to more than 35 countries. Its headquarters are located in the city of Não-Me-Toque, in the state of Rio Grande do Sul, and has two branch factories located in Carazinho (RS) and Santa Rosa (RS). Today, it employs more than 2.500 workers distributed across the various sectors of its factories and branches. Its product portfolio covers the areas of precision agriculture, agricultural trailers, distributors, soil levelers, agricultural planers, corn harvester platforms, sprayers, subsoilers, planters, seeders, scarifiers and tractors, in addition to a line of lubricants and nozzles of spraying. It presents itself as a dynamic company with a technological vocation, always looking for innovations and technologies that meet the needs of rural producers and generate increased productivity and profit in the activity. The company bases its production on five values: constant evolution, awareness of quality, appreciation and respect for people, integrity with all audiences and simplicity.