Progress report for FNC23-1363
Project Information
Robert Braun, is currently a full-time Farmer with over 45 years of combined full-time and part-time farming experience. Robert is an ASE Master Mechanic with over 40 years in the field and 18 years as a professional educator at two Wisconsin Tech Colleges in their auto, truck, equipment, and renewable energies programs. Robert has an extensive background in practical tractor repair and modifications to optimize utility and minimize environmental impact.
With 17 patents to his credit, Robert also has extensive experience in comprehensive research, design, patenting, prototyping and testing of solution-based mechanical equipment. Robert has received and administrated multiple grants throughout his career.
Robert’s career experience includes:
• Soil rehabilitation / Organic vegetable production / Pastured beef & poultry / Renewable energies
• WIDS format technical curriculum development and delivery
• Educational outreach and video production
• Hands-on technical instruction of gas and diesel power plant technology
• Hands-on equipment and repair/service procedure training
• Field research and analysis
• Repair technology design & development
• Project management
• Government grant proposal preparation / fulfillment / administration
• Video / audio production and editing
Brian Buckta, proprietor of Written Impressions, is a career professional specializing in outreach and administration of sustainable agriculture and renewable energies initiatives. Brian and Robert have worked together on multiple successful projects over the past 30 years.
Brian’s career experience includes:
• Environmental air-quality programs design, administration and implementation
• USEPA Environmental Standards document preparation
• Composition of agricultural / environmental / renewable energies / educational grant proposals
• Technical curriculum development and implementation / WIDS format
• Consumer and commercial sales & customer-service communications engineering, authorship and
implementation
• Business & marketing plan development, authorship and implementation / field research and analysis
• Development and implementation of marketing communications systems
• HACCP / SSOP development / forms design and administration
• Project management / event coordination / public speaking
• Extensive technical writing
• Published automotive / environmental author
Established in 2003, Pigeon River Farm is a family owned and farmed 50-acre Organically-Operated facility located on the southern branch of the Pigeon River near Clintonville in Waupaca County, Wisconsin. Pigeon River Farm’s AWA certified chickens and livestock are pastured according to free range, rotational grazing practices. Pigeon River Farm’s livestock and chickens are rotated through paddocks of high-quality legumes and grasses. Pigeon River Farm also utilizes a solar PV system to generate electrical power.
Due to the increasingly high cost of new tractors, most small farms simply cannot afford them. Most small farms rely on older petroleum-fueled utility tractors with poor fuel efficiency. This places most small farms at the mercy of petroleum fuel prices to maintain economic sustainability. Unfortunately, older petroleum-fueled utility tractors also usually represent a high carbon footprint and require ongoing maintenance with heavy use.
New electric farm tractors can cost 20-35% more than comparable diesel or gas tractors. Although affordable full-electric drive tractor conversion options are available, these conversions generally limit a tractor to light-duty and/or short-lived tasks. Most farmers will ultimately be forced to revert to their time-tested petroleum-fueled tractors to complete many tasks on the farm.
No options are currently available for an affordable, versatile hybrid dual-fuel tractor conversion that will allow a tractor to perform all the necessary tasks on the farm.
Farmall M Tractor That Will be Used for the Project
A hybrid dual-fuel tractor conversion will ultimately boost economic farm sustainability through petroleum fuel reduction. This is especially if on-farm solar power is available. A hybrid dual-fuel tractor conversion will ultimately boost ecological sustainability through carbon emissions reduction, and social sustainability through a public perception of responsible environmental stewardship.
While the maximum efficiency of an internal combustion engine running on petroleum fuel is around 33%, direct-drive electric motors average around 90% efficiency. Much like a hybrid electric car, a dual-fueled tractor will give the farmer the benefits, range, and power of both electric and petroleum fuels. The conversion will also include on-board electrical regeneration features.
The on-board technology provided by the conversion will primarily utilize electric power, and it will automatically engage gasoline power when needed to meet power demands for specific tasks. The system components and software will be fine-tuned during the 1-year testing period to provide optimal results.
- An initial benchmark will be determined by measuring fuel consumption of the test tractor “Farmall M” in actual service on the farm. All tasks will be recorded.
- Necessary equipment will be ordered.
- The test tractor “Farmall M” will be taken out of service to begin the conversion. Each step of the conversion process will be recorded with video footage. An open house will be scheduled once each month during the project build so interested farmers can see the progress on the buildout of the system.
- Video and still photos will be posted online during every step of the project on YouTube, Facebook, and other online venues.
- When the prototype is built, the hybrid tractor utility and fuel consumption will be tested and recorded in common on-farm applications over the course of 1 year. In addition to traditional local farming community promotional channels, live events on Facebook and YouTube are planned to show the hybrid system in action in all seasons throughout the year. Live videos will highlight each project milestone and each new task such as cutting hay, moving wagon, etc., and important system hardware or software information.
- A field day will be held at Pigeon River Farm to share the full project details with the local farming community and provide a live demonstration of the prototype tractor.
- Live demonstrations of the prototype tractor will be presented at the annual Midwest Renewable Energy Association (MREA) Conference and at the Annual Central Wisconsin Tractor Show. In addition, classroom presentations and live demonstrations will be offered to Marion High School FFA and the Fox Valley Technical College Agriculture Program.
- The project will provide video data and print reporting on the full details of conversion process and comprehensive project results will be produced that may be used for further outreach and tutorials.
Project Objectives:
- Establish benchmarks by measuring gasoline consumption of test tractor in common farm usage.
- Modify Farmall M tractor with a hybrid gasoline / electric dual fuel drive system.
- Test and record hybrid tractor utility and fuel consumption in common on-farm applications over the course of 1 year.
- Provide ongoing outreach activities to the local farming community throughout the course of the project.
- Provide video data and print reporting on conversion process and project results that may be used for outreach and future tutorials.
Cooperators
- - Technical Advisor (Researcher)
Research
Review of Phase 1
Phase 1 of our project has reached its completion, barring the pending field testing, which is contingent on favorable weather conditions for tractor operations. This phase was pivotal in garnering feedback from the twelve participants who have been actively engaged since the project's inception.
Participant Feedback and Skill Assessment
A critical aspect of this phase was evaluating the project's practicality based on the participants' skill levels. Feedback was dichotomous: half of the participants felt confident in executing the tasks with the aid of instructional videos and detailed photographic documentation provided during the development phase. The remaining participants indicated reliance on skilled mechanics within their networks to assist in the process. This split underscores the importance of accessibility and varying skill levels in the farming community.
Component Selection and Design Simplification
The components for this project were meticulously chosen to balance simplicity and the inherent complexity of such systems. Two primary objectives drove this decision: ensuring ease of service in the future and facilitating procurement for potential future expansions by other farmers. The feedback received has been instrumental in refining some of the component designs, making them more user-friendly and efficient.
Outreach and Community Engagement
Our outreach efforts, encompassing multiple YouTube videos, television interviews, and magazine features, have significantly broadened the project's visibility. This has sparked engaging and insightful conversations with farmers beyond our initial participant group, indicating a growing interest and potential impact in the wider agricultural community.
Prototype and Upcoming Field Testing
The prototype, now ready for application, is poised to undergo field testing. This testing is crucial to determine the energy index of conventional fuels versus the solar photovoltaic energy required to power the electric drive component of the system. The participating farmers have expressed keen interest in this aspect, eagerly anticipating both the process and the outcomes of these tests.
Conclusion and Forward Look
The completion of Phase 1 marks a significant milestone in our project. The feedback and insights gained have been invaluable in refining our approach and preparing for the critical field testing phase. We anticipate that the results of this testing will provide compelling data on the efficiency and viability of integrating solar energy into farming operations, offering a potentially transformative approach to energy use in agriculture.
Educational & Outreach Activities
Participation Summary:
2023 Outreach Activities to date:
Video 1 March 5th https://youtu.be/hut756ui544
Shop meeting on March 25th to review the project with five local Farmers. Finalize the motor and battery mounting design.
Video 2 April 2nd https://youtu.be/fxXZ6f_lOWg
Video 3 July 16th https://youtu.be/N-wOzRb9TlQ
Video 4 July 31 https://youtu.be/N-wOzRb9TlQ
Wisconsin State Farmer Newspaper July 26th $15K grant to help Marion farmer convert Farmall into dual-fuel tractor (wisfarmer.com)
Video 5 Sept 15th https://youtu.be/iKc_eMzw8hs
Review meeting on Nov. 25th Review the wiring system.
Video 6 Dec 13th https://youtu.be/EWexT8AjLlM
Video of the Hybrid tractor on channel 5 Greenbay WI. The segment starts at 8:30 on the timecode.
https://www.youtube.com/watch?v=udQqFlh0qVw&t=515s
Part 2 Video of the Hybrid tractor on Channel 5 Greenbay WI. The segment starts at 8:11 on the timecode.
Midwest Farm Weekly 12/30/2023 | WFRV Local 5 - Green Bay, Appleton (wearegreenbay.com)
2024 Outreach Activities to date:
Video 7 July 3rd 2024: https://youtu.be/5tW_GPgYlBk
Field day demo: On July 20th, 2024, I showed 12 local farmers the Hybrid tractor in action, running on electricity and using a 3-point fence trimmer.
Tractor show: On July 27th, 2024, the "MAHS" Marion Area Historical Society Heritage Days tractor show took place. More than 500 people attended the show, and I talked to more than 100 people about it and presented photos of the tractor's build and operation.
Learning Outcomes
Learning from the Grant: Navigating Supply Line Challenges
A significant lesson learned during this project was the complexity and unpredictability of supply lines. Initially, we anticipated a straightforward process in acquiring the necessary components. However, the reality proved more challenging than expected. As we delved into the procurement phase, we encountered backorders and delays, particularly for unique and diverse components essential to our prototype.
This issue was not unique to our project. During the focus groups conducted in the first half of the project, we found that many farmers shared similar experiences with component delays over the past few years. Despite these challenges, our team demonstrated resilience and adaptability. We were able to navigate around these problems, and in some instances, we sourced higher-quality components for the same price. This success can be attributed to the invaluable recommendations from farmers who participated in our focus groups, suggesting alternative suppliers they had previously used.
Impact on Farm/Ranch Operation
Despite the initial setbacks, the component shortage did not majorly derail our project timeline. We are currently on target, with a functional prototype ready for testing as soon as weather conditions permit. This experience underscored the importance of involving talented and resourceful individuals early in the project who can provide solutions when unexpected issues like sourcing arise.
Advantages and Disadvantages of Implementing the Project
The project's implementation brought forth several advantages, including enhanced problem-solving skills, a better understanding of supply chain dynamics, and strengthened community ties through collaborative efforts. However, it also highlighted the disadvantages, such as the vulnerability of farm operations to supply chain disruptions and the need for effective contingency planning.
Recommendations for Other Farmers or Ranchers
Based on our experiences, we recommend other farmers and ranchers embarking on similar projects actively engage with their community and establish a network of reliable suppliers. It's crucial to plan for potential supply chain disruptions and have alternative sourcing strategies. The collective wisdom and experience of the farming community can be an invaluable resource in navigating these challenges.
Conclusion
The journey through this SARE grant project has been enlightening and transformative for our farm operation. It has taught us the significance of community collaboration, the need for flexibility in project planning, and the importance of being prepared for supply chain uncertainties. These learnings are not just pivotal for our operation but also hold valuable insight for the broader farming community, emphasizing the role of grants like SARE in fostering innovation and collective growth in sustainable agriculture.
Project Outcomes
The positive feedback I've received has been incredibly uplifting, not just from our focus group participants but also from other farmers who've learned about our project and contacted me about the idea of integrating renewable energy into our farming operations. The potential to harness this energy effectively is a promising aspect of our work. Moreover, the coverage in agricultural publications and television interviews has piqued my interest even further. I am eager to see the level of interest once our hybrid tractor is operational in the fields, demonstrating the concept's viability. Some farmers have expressed concerns about their ability to handle the technical aspects of assembling such a product. I believe that providing more comprehensive written documentation and instructional videos could greatly alleviate these concerns.
Data Report Draft: Fall 2024
Hybrid Tractor Project - Final Report Draft
Preamble
This report outlines the development, testing, and performance analysis of a hybrid tractor system that integrates an electric drive with a conventional gasoline-powered engine. The primary objective of this project was to explore the operational feasibility, efficiency, and financial impact of utilizing electric power, with a focus on the tractor’s performance under real-world farming conditions. The testing was conducted over a summer season on tasks such as raking hay, trimming fence lines, spreading fertilizer, and spraying liquids. A key component of this project was to compare the efficiency of the two drive systems—electric and gasoline—while considering the financial benefits of leveraging the farm’s existing solar photovoltaic (PV) system to power the electric system.
System Design and Build
The hybrid tractor system was developed by retrofitting a traditional tractor with a Warp 9 electric motor powered by Group 30 industrial-grade batteries delivering 144 volts. The design included a custom speed control governor to maintain a constant speed under variable loads, similar to a throttle in modern vehicles. A high-voltage relay and controller managed the flow of power to ensure safe and efficient operation.
Key Modifications:
Belt Pulley Replacement: A dual-belt pulley was installed for reliable power transmission from the electric motor to the tractor’s Belt Pully Takeoff (BPT)
Motor to BTO Ratio: The electric motor, running at 3,600 RPM
, was calibrated to drive the PTO at 540 RPM, with a target of 540 RPM.
Battery and Power Management: The system was configured with a 200-amp limit to
overloading the batteries, maintaining efficiency and longevity.
Monitoring Systems: A digital current sensor was installed to monitor load and energy consumption in real time.
Application Testing Overview
The following tasks were conducted to compare the electric and gasoline systems under various operational conditions:
Task 1: Fence Line Trimming (Lightest Task)
Description: A 3-point-mounted string trimmer was used to trim fence lines for 3 hours.
Electric System Performance: The task consumed 2.5 kWh per hour, totaling 7.5 kWh for the 3-hour session.
Gasoline System Performance: Consumption averaged 1 gallon per hour, totaling 3 gallons for the session.
Cost Comparison:
Electric (Grid Power): 7.5 kWh × $0.12 = $0.90
Gasoline: 3 gallons × $3.00 = $9.00
Savings using Solar: $9.00 (Gasoline) – $0 (Solar) = $9.00 saved
Task 2: Raking Hay (Heaviest Task)
Description: Raking hay was performed for 2 hours, covering 2 to 3 acres.
Electric System Performance: The electric drive consumed 4.5 kWh per hour, totaling 9.0 kWh for the session.
Gasoline System Performance: The gasoline engine consumed 1.5 gallons per hour, totaling 3 gallons for the session.
Cost Comparison:
Electric (Grid Power): 9.0 kWh × $0.12 = $1.08
Gasoline: 3 gallons × $3.00 = $9.00
Savings using Solar: $9.00 (Gasoline) – $0 (Solar) = $9.00 saved
Intermediate Task Example: Spreading Fertilizer
Estimated Energy Consumption: 3.5 kWh per hour (midpoint between light and heavy tasks).
Solar Hours Supported: With 65 kWh available per day, solar can support 18.6 hours of this task.
Technical Data and Solar Feasibility
Solar Output and Task Support
The farm’s solar PV system generates 65 kWh per day, which is equivalent to:
Fence Line Trimming: 26 hours (2.5 kWh per hour)
Raking Hay: 14.4 hours (4.5 kWh per hour)
Grid Power Equivalency
Using grid power to run the tractor for these tasks would cost:
Fence Line Trimming: 7.5 kWh × $0.12 = $0.90
Raking Hay: 9.0 kWh × $0.12 = $1.08
Compared to gasoline, solar power offers substantial savings. Even in the absence of sufficient solar output, grid power remains a more economical option.
Operational Observations
Electric System:
Strengths:
Superior at low-speed, precise tasks like fence trimming.
Quiet operation with zero emissions when using solar energy.
Limitations:
Higher energy consumption for heavy tasks like raking hay.
Lack of a clutch can lead to slower spooling during PTO tasks.
Gasoline System:
Strengths:
Handles heavy loads efficiently with stable fuel consumption.
Faster acceleration and smoother transitions due to the clutch.
Limitations:
Less efficient at low-speed tasks.
Higher operational costs and emissions.
Financial Analysis
The following table summarizes the financial impact of using solar, grid, and gasoline power for different tasks:
Task Electric Energy Used (kWh) Grid Power Cost (USD) Gasoline Cost (USD) Savings (Solar vs. Gasoline) (USD) Solar Hours Required
Fence Line Trimming (3 hrs) 7.5 $0.90 $9.00 $9.00 1.38
Raking Hay (2 hrs) 9.0 $1.08 $9.00 $9.00 3.32
Conclusion
The hybrid tractor project demonstrated significant potential for cost savings and operational efficiency by utilizing solar power. Lighter tasks such as fence line trimming are easily supported by the farm’s solar PV system, while heavier tasks like raking hay consume more energy but still offer financial advantages over gasoline.