In order to solve the problems of poor stability of the output speed and poor synchronization of the pump-controlled dual motor in a hydraulic travel system during step input speed and external load disturbance, different control strategies were designed and compared with the state machine using the statechart module control, Z-N frequency response PID control, and GA-based PID parameter self-tuning methods. Our analysis shows that the BP algorithm-based PID parameter self-tuning control method has no overshoot and that the three methods reduced the target speed tracking time by 90.11%, 75.12% and 36.55%, respectively. The average synchronous error for the system output speed was 7.95%. The stability and synchronization requirements of the constant speed of the hydraulic travel system were satisfied. These research results can provide a reference for the design and application of constant speed control for pump-controlled dual-motor hydraulic travel systems in the fields of engineering and agricultural machinery.

This study is based on the influence of power shift control on the smoothness of cotton picker shifts and proposes an optimization method for the smoothness of power shifts with different control strategies for the gearbox. Through the structural design of the power shift mechanism control module, the hydraulic power distribution of the hydraulic system of the hydraulic travel module and its control mode are analyzed, and a regional cooperative shift control strategy is proposed in conjunction with control theory. A model of cotton picker dynamics was built using AMESim simulation software. In addition, the traditional control strategy was simulated and compared with the Statement component automatic control strategy to analyze and discuss the control deficiencies in power shift smoothness. Then, a particle swarm genetic algorithm (PSGA) was constructed by integrating the PSO algorithm and the genetic algorithm to verify the effectiveness of the algorithm in improving the dynamic performance and shift smoothness of the gearbox. The algorithm was verified using bench tests, and the algorithm improved the harvesting quality and efficiency of the cotton picker.

To meet the working performance demand of cotton pickers, a hydrostatic power shift composite drive system design is proposed. This study aims to enhance the driving function of the cotton picker in various working conditions and improve its adaptability by combining a hydrostatic speed control system with a mechanical power shift structure. To achieve this, a single variable pump + double variable motor closed circuit is adopted. By adjusting the pump and motor displacement in stages, the driving speed of the cotton picker can be optimized for different working conditions. Additionally, the power shift mechanism is employed to increase the speed range and improve the transmission efficiency, enabling higher speeds to be achieved. Firstly, the main components of the composite drive system were calculated and selected, and then AMESim software was used for modeling and simulation analysis, and the results are as follows: When the cotton picker starts and picking operation stage variable displacement pump + fixed displacement dual motor speed control, the highest driving speed is 8.5 km/h. During the field and road transport operation stage fixed displacement pump + variable displacement dual motor speed regulation, the highest speed of 14.5 km/h was achieved in the field. When transferring to the road, the instant mechanical power shift speed and, the highest speed on the road was up to 27.5 km/h. Finally, the field experiment and speed ratio analysis of the drive system was conducted, and the average error of the experimental speed measurement was 0.588%. The speed ratio matching was in line with the design expectation. The results show that the hydrostatic power shift composite drive system designed in this study has good driving adaptability and can effectively meet the functions of cotton picker field picking, transport operation and road transportation in transit, which provides theoretical support for the design of cotton picker chassis drive system.

In response to the issues of slow dynamic response, uneven shifting, and strong jolting during the starting and shifting operations of the cotton picker, we established a model for automatic power shifting control. We proposed optimization strategies using the Statechart logic control method and BP neural network control method. Different control effects were analyzed concerning pressure, flow rate, motor speed, vehicle speed, impact degree, and slip-grinding work. The results showed that the Statechart logic control method increased the response time of the flow rate by 46.67% during the starting process, with a good linear characteristic during the variation. It reduced the impact during starting and shifting by 38.57% and 67%, and the sliding friction power during starting and shifting by 51.95% and 33.33% respectively. The BP neural network control method reduced the pressure overshoot during starting and shifting by 25% and 30.77%, respectively, demonstrating better robustness. The pump, motor speed, and vehicle speed showed smooth growth after starting and shifting, with faster vehicle speed response during the starting process. Additionally, the vehicle speed overshoot during shifting significantly decreased, ensuring overall performance that meets the operational requirements of the cotton picker. This finding holds practical significance for the advancement of control strategy optimization and the development of the control system for the powershift gearbox in cotton pickers.

To overcome the issue of unstable speed output encountered by cotton pickers operating in harsh environments and subject to frequent external load fluctuations, a hydraulic–mechanical transmission (HMT) for cotton pickers is proposed in this study. By analyzing the driving system of the cotton picker, a Lavira-based HMT scheme is developed. The matching characteristics of the HMT speed ratio are analyzed, a continuity and smoothness test of the speed ratio of the changing segment is carried out, and the influence law of smoothness of the HMT changing segment is discussed. The results show that the HMT system effectively satisfies the driving speed requirements for both field harvesting and road transportation of cotton pickers. The HMT speed ratio is continuously controllable and the design is reasonable. The HMT load torque and the oil pressure in the main oil circuit have a significant impact on the smoothness indicators of speed reduction and dynamic load. Additionally, the flow rate of the governor valve has a notable effect on the smoothness indicator of sliding friction power. However, the engine’s output speed has no significant influence on the HMT’s smoothness. This research can provide theoretical support for the development and design of cotton picker gearboxes and the transmission characteristics and experimental research of off-road vehicle gearboxes.

The control strategy of a power shift system has a significant impact on the driving stability and comfort of cotton pickers. To prevent the cotton picker from stopping to shift and reduce the jerks while shifting, in this study, the power shift system of a four-speed cotton picker was taken as the research object, and the working principles of the power shift transmission of the cotton picker and the hydrostatic transmission were analyzed. Firstly, the intelligent fuzzy control strategy of the variable pump and dual variable motor displacement of the cotton picker power shift system was designed using a fuzzy algorithm, and two-input and three-output fuzzy controllers were constructed with the engine rotational speed and vehicle speed as the input parameters, and the variable pump displacement, front motor displacement, and rear motor displacement as the outputs. Secondly, the model of the whole vehicle travel drive system of the cotton picker was constructed using co-simulation of Amesim and Simulink. Finally, the influence of the fuzzy shift control strategy and conventional manual shift method on the speed and driving distance of the cotton picker was compared and analyzed. The analysis results show that the fuzzy algorithm-based control strategy of the power shift system of the cotton picker can ensure that the cotton picker travels stably according to the target speed, and effectively reduces the speed fluctuation and jerks while shifting. The results of the study are of great significance to realize the non-stop shifting of the cotton picker as well as improve the stability and smoothness of the shift while driving.