Design and Simulation of a Three-DOF Profiling Header for Forage Harvesters in Hilly Terrain

To address the problems of uneven stubble height and high missed-cutting rate caused by the insufficient profiling capability of traditional forage harvesters in complex hilly terrain, this paper designs a three-degrees-of-freedom (DOF) profiling header primarily for typical hilly terrain with gentle slopes of 8–15°. Through pitch, roll, and height adjustments, it stably maintains stubble height at 150 mm. Subsequently, geometric analysis and structural optimization achieved kinematic decoupling among all degrees of freedom, thereby overcoming the inherent limitations of the two-DOF header, such as poor adaptability to longitudinal slope and strong adjustment coupling. Three-dimensional modeling was completed in SolidWorks, multibody dynamics simulation was performed in ADAMS, and a profiling control system incorporating a hydraulic system, multi-source sensor fusion, and a fuzzy PID controller was built. The dynamics simulation results show that under the working conditions of 15° longitudinal and 10° transverse slopes, the stubble height error of the header is controlled within 10%, the attitude angle adjustment error is less than 0.5°, and the dynamic response is excellent. Prototype field tests showed that, compared with the two-DOF header, the three-DOF profiling header improved the stubble height stability by about 35%, reduced the missed-cutting rate by about 5%, and increased the operating efficiency by about 15%. No cutting blade contact with the soil occurred, verifying the rationality of the mechanism design and its adaptability to terrain. This study provides an effective technical solution for improving the mechanization level of forage harvesting in hilly and mountainous areas.