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.