A combine harvester unloading system and control method

Abstract

The present application belongs to the field of agricultural machinery, and particularly relates to a combine harvester unloading system and a control method. The system comprises: a grain bin, a grain bin residual amount sensor arranged on the grain bin; a first unloading cylinder, which is in communication with the grain bin and can be driven by a first driving mechanism to rotate in a horizontal direction relative to the grain bin to adjust a horizontal rotation angle; a second unloading cylinder, which is in communication with the first unloading cylinder and can be driven by a second driving mechanism to rotate in a vertical direction relative to the first unloading cylinder to adjust an elevation angle; and a auger mechanism arranged in the first unloading cylinder and the second unloading cylinder. The present application acquires parameters such as the unloading cylinder rotation angle, grain flow and grain bin residual amount in real time through a sensing detection mechanism, combines a PLC controller and a multi-modal collaborative control module, realizes full-automatic closed-loop control of unloading cylinder posture adjustment, auger rotation speed adjustment and system reset action, replaces the traditional manual operation mode, significantly reduces the labor intensity of the driver, and improves the operation precision and response speed.

Description

Technical Field

[0001] This invention belongs to the field of agricultural machinery, and in particular relates to a combine harvester unloading system and control method. Background Technology

[0002] In modern large combine harvesters, grain is typically unloaded from the grain bin into the transport hopper via an unloading hopper and an internal unloading auger. Traditionally, the position adjustment of the unloading hopper relies primarily on manual operation. The operator must manually control the rotation angle and position of the hopper during unloading and judge the unloading speed based on experience. This manual method has several drawbacks: manual adjustment increases the operator's workload, and during continuous operation, delays or inaccuracies can occur; if the angle and orientation of the unloading hopper are not precisely controlled, grain may spill or fail to be accurately unloaded into the hopper.

[0003] Existing combine harvester unloading augers typically operate at a fixed speed, unable to intelligently adjust according to grain flow. This can easily lead to blockages or overflows when the grain flow is too high, while insufficient flow reduces unloading efficiency. Current technology lacks an intelligent system capable of automatically adjusting the unloading auger's posture and controlling the unloading flow based on actual unloading conditions. Therefore, improvements are needed to enhance unloading efficiency, reduce manual intervention, and prevent grain waste. Summary of the Invention

[0004] In view of the difficulties in adjusting the position of the unloading hopper and the fixed speed of the unloading auger in the existing technology, which cannot be intelligently adjusted according to the grain flow rate, the present invention provides an intelligent control system for the unloading hopper of a combine harvester, which can overcome some of the defects of the existing technology.

[0005] A combine harvester unloading system according to the present invention includes:

[0006] A grain warehouse, on which a grain level sensor is installed;

[0007] The first unloading hopper is connected to the grain silo and can be driven by the first driving mechanism to rotate horizontally relative to the grain silo to adjust the horizontal angle.

[0008] The second unloading hopper is connected to the first unloading hopper and can be driven by the second drive mechanism to rotate vertically relative to the first unloading hopper to adjust the elevation angle.

[0009] An auger mechanism is provided inside the first unloading drum and the second unloading drum. The auger mechanism is used to transport the grain that enters the first unloading drum from the grain silo through the first unloading drum and the second unloading drum to the unloading port at the end of the second unloading drum and unload it into the transport vehicle hopper.

[0010] A photoelectric sensor is installed inside the second unloading hopper to detect the grain flow rate inside the second unloading hopper.

[0011] Preferably, the bottom end of the first unloading hopper is connected to a first driving mechanism, the first driving mechanism comprising:

[0012] Mounting base, connected to the grain silo;

[0013] A drive motor is mounted on the mounting base;

[0014] The drive gear is connected to the output shaft of the drive motor;

[0015] The driven gear meshes with the driving gear and is connected to the first unloading cylinder by fasteners, so as to drive the first unloading cylinder to rotate horizontally relative to the grain bin and adjust the horizontal angle.

[0016] Preferably, a second driving mechanism is connected to the top of the first unloading hopper, the second driving mechanism comprising:

[0017] The connecting cylinder has its first end hinged to the top of the first unloading cylinder and its second end fixedly connected to the end of the second unloading cylinder away from the unloading port.

[0018] A hydraulic cylinder is installed on the first unloading cylinder. The telescopic end of the hydraulic cylinder is connected to the second unloading cylinder so that the first unloading cylinder can be rotated vertically to adjust the elevation angle through the telescopic movement of the hydraulic cylinder.

[0019] Preferably, an angle sensor is provided at the hinge position of the connecting cylinder and the first unloading cylinder. The angle sensor is used to detect the angle between the second unloading cylinder and the connecting cylinder relative to the first unloading cylinder to determine the elevation angle.

[0020] As a preferred option, it also includes:

[0021] An industrial camera is installed at the unloading port and is used to acquire real-time images of the inside of the transport vehicle.

[0022] The present invention also provides a control method for a combine harvester unloading system, which is based on the aforementioned combine harvester unloading system, the control method comprising:

[0023] In response to the grain silo balance sensor detecting that the grain silo balance has reached a preset threshold, a grain unloading command is triggered.

[0024] In response to the unloading command, the action strategy is determined based on the preset position coordinate parameters of the transport vehicle bed;

[0025] According to the action strategy, the first and second unloading cylinders are rotated into position so that the unloading port is aligned with the center of the transport vehicle bed and the auger mechanism is started to unload the grain at the initial speed.

[0026] During the unloading process, based on the grain silo balance detected by the grain silo balance sensor, the environmental parameters detected by the pre-positioned environmental sensors, and the position coordinate parameters of the transport vehicle bed, it is determined whether it is necessary to enter a specific control mode.

[0027] If a specific control mode needs to be entered, the auger mechanism, the first drive mechanism, and the second drive mechanism shall be controlled according to the specific control mode.

[0028] If a specific control mode is not required, the auger mechanism can be controlled in stages based on the grain flow detected by the photoelectric sensor.

[0029] Preferably, the remaining grain storage capacity is pre-set with a first threshold and a second threshold that increase sequentially; the environmental parameters include wind speed and terrain inclination.

[0030] The step of determining whether to enter a specific control mode includes:

[0031] If the remaining grain in the grain bin is greater than the second threshold and the position coordinate parameters of the transport vehicle are fixed, the high-load mode is entered.

[0032] If the remaining grain storage capacity is less than the first threshold and the wind speed and terrain inclination are both less than the corresponding thresholds, the energy-saving mode is entered.

[0033] If both the wind speed and the terrain tilt angle are greater than the corresponding threshold, enter the anti-interference mode;

[0034] The priority order is anti-interference mode, high load mode, and energy saving mode.

[0035] Preferably, the PWM duty cycle of the auger mechanism motor is preset with a first duty cycle, a second duty cycle, and a third duty cycle that increase sequentially.

[0036] The rotational speed of the auger mechanism is preset to have a first rotational speed, a second rotational speed, a third rotational speed, a fourth rotational speed, a fifth rotational speed, and a sixth rotational speed that increase sequentially; the third rotational speed is used as the initial rotational speed.

[0037] The grain flow rate is preset with a first flow rate and a second flow rate that increase sequentially.

[0038] When it is determined that a specific control mode needs to be entered:

[0039] The control strategy for the high-load mode includes adjusting the PWM duty cycle of the auger mechanism to the third duty cycle and the rotation speed of the auger mechanism to the sixth rotation speed; controlling the second drive mechanism to adjust the elevation angle of the second unloading cylinder to the corresponding preset value; and controlling the first drive mechanism to keep the unloading port aligned with the center of the transport vehicle hopper.

[0040] The control strategy of the energy-saving mode includes controlling the rotation speed of the auger mechanism within the range between the second and fourth rotation speeds, and keeping the second drive mechanism in a low-power mode.

[0041] The control strategy of the anti-interference mode includes enabling overload protection for the motor of the auger mechanism, increasing the output torque of the motor from the default value to a preset ratio, controlling the second drive mechanism to lower the elevation angle of the second unloading cylinder to the corresponding preset value, and calibrating the horizontal rotation angle of the first unloading cylinder at preset intervals to compensate for the offset caused by wind or slope.

[0042] When it is determined that entering a specific control mode is not necessary:

[0043] If the grain flow rate is greater than the second flow rate, the PWM duty cycle of the auger mechanism motor is adjusted to the first duty cycle, and the speed is adjusted to the first speed.

[0044] If the grain flow rate is greater than the first flow rate and less than the second flow rate, the auger mechanism maintains its current rotation speed.

[0045] If the grain flow rate is less than the first flow rate, the PWM duty cycle of the auger mechanism motor is modulated to the second duty cycle, and the speed is adjusted to the fifth speed.

[0046] Preferably, the control method further includes:

[0047] If the grain flow rate is lower than the preset flow rate lower limit for a continuous period of time, the rotation speed of the auger mechanism will be reduced by a preset percentage at each preset time interval until the rotation speed is reduced to the preset rotation speed lower limit. At the same time, the elevation angle of the second unloading hopper will be adjusted down by a preset angle at each preset time interval until it returns to zero.

[0048] Preferably, the control method further includes:

[0049] If the grain silo balance sensor detects that the grain silo balance is less than the preset lower limit value, and the grain flow is zero and continues for more than the corresponding preset time, a stop signal is sent to the auger mechanism.

[0050] In response to the stop signal, the auger mechanism stops operating and controls the first drive mechanism and the second drive mechanism to reset;

[0051] The resetting of the first and second drive mechanisms includes:

[0052] The second drive mechanism is controlled to lower the elevation angle of the second unloading hopper at a corresponding preset angular velocity until it reaches the initial zero position;

[0053] The first drive mechanism is controlled to return the horizontal rotation angle of the first unloading hopper to the initial zero position at a corresponding preset angular velocity.

[0054] The control method further includes:

[0055] If the horizontal rotation angle of the first unloading hopper or the elevation angle of the second unloading hopper deviates from the corresponding preset threshold for more than a preset time relative to the target angle, an action stop command is triggered, and the current state is maintained and stopped.

[0056] The control method further includes:

[0057] If the grain-covered area in the real-time image of the transport truck bed captured by the industrial camera at the unloading port is empty, and the grain flow detected by the photoelectric sensor is above the corresponding preset threshold, an alarm command will be triggered to prompt manual verification of the industrial camera or cleaning of the lens.

[0058] The control method further includes:

[0059] Based on real-time image processing of the transport truck bed captured by industrial cameras, abnormal areas with insufficient grain coverage in the transport truck bed were identified.

[0060] Based on the center coordinates of the abnormal area, adjust the rotation angles of the first and second unloading cylinders so that the unloading port is aligned with the abnormal area for unloading.

[0061] Compared with the prior art, the present invention has the following significant advantages:

[0062] (1) The present invention can collect the grain warehouse balance in real time, and based on the grain warehouse balance and the pre-acquired environmental parameters and the position coordinate parameters of the transport vehicle, comprehensively consider whether it is necessary to determine whether to enter a specific working mode, and automatically control the first unloading hopper, the second unloading hopper and the auger mechanism according to the specific control strategy under the specific working mode to adapt to various actual working conditions. In this way, the unloading operation can be kept safe and stable under various working conditions as much as possible. If it is not necessary to enter a specific working mode, the unloading mechanism is controlled in stages according to the grain flow rate, thereby improving the unloading efficiency as much as possible while ensuring safety. The present invention can replace the traditional manual operation mode through fully automatic closed-loop control, significantly reducing the labor intensity of the driver and improving the operation accuracy and response speed.

[0063] (2) This invention introduces an image recognition module, which uses an industrial camera to capture images of the inside of the transport truck bed. This module can automatically identify areas in the truck bed where grain has not been fully unloaded and feed back the coordinates of the abnormal areas as target areas to the PLC controller. By comparing these coordinates with the current posture of the unloading hopper, the system automatically generates the required horizontal rotation adjustment of the first unloading hopper and the elevation adjustment of the second unloading hopper, thereby achieving precise correction of the unloading direction and further improving the accuracy and efficiency of unloading.

[0064] (3) When the grain silo's remaining volume drops to the threshold or the flow rate remains too low, the system automatically initiates a gradual deceleration program, gradually reducing the auger speed and decreasing the elevation angle of the second unloading hopper to prevent residual grain from accumulating. During the reset process, the angle sensor monitors the position deviation throughout. If the reset is abnormal, an alarm is triggered and the system is locked to ensure safe and reliable operation. Attached Figure Description

[0065] Figure 1 This is a schematic diagram of the structure of the combine harvester unloading system in this invention;

[0066] Figure 2 yes Figure 1 A structural diagram from another perspective;

[0067] Figure 3 This is a schematic diagram of the structure of the first driving mechanism of the present invention;

[0068] Figure 4 This is a schematic diagram showing the position of the photoelectric sensor of the present invention;

[0069] Figure 5 This is a schematic diagram of the position of the industrial camera of the present invention.

[0070] Figure 6 This is a flowchart of the grain unloading process of the present invention;

[0071] Figure 7 This is a flowchart of the grain flow monitoring process of the present invention.

[0072] Numbered in the diagram: 1. Industrial camera; 101. Camera body; 102. Camera mounting base; 2. Grain unloading port; 3. Second grain unloading cylinder; 4. Hydraulic cylinder; 5. Angle sensor; 6. Connecting cylinder; 7. First grain unloading cylinder; 8. First drive mechanism; 801. Drive motor; 802. Drive gear; 803. Driven gear; 804. Fastener; 9. Grain bin remaining amount sensor; 10. Screw mechanism; 11. Screw shaft; 12. Photoelectric sensor; 1201. Sensor base; 1202. Sensing element. Detailed Implementation

[0073] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more. In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art will understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0074] The present invention will be further described below with reference to the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solution of the present invention, and should not be used to limit the scope of protection of the present invention.

[0075] Example 1

[0076] To make the purpose, technical solution, and advantages of this invention patent clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments.

[0077] Combination Figures 1-5 This embodiment provides a combine harvester unloading system, which includes a grain bin, a first unloading cylinder 7, a second unloading cylinder 3, an auger mechanism 10, and a photoelectric sensor 12.

[0078] A grain silo balance sensor 9 is arranged on the grain silo. In a specific embodiment, the grain silo balance sensor 9 can determine the grain silo balance by visual image or by grain weight, or it can be a sensor with the same function that is already available in the prior art. This embodiment does not make any specific limitations.

[0079] The first unloading hopper 7 is connected to the grain silo and can be driven by the first drive mechanism 8 to rotate horizontally relative to the grain silo to adjust its horizontal angle. The second unloading hopper 3 is connected to the first unloading hopper 7 and can be driven by the second drive mechanism to rotate vertically relative to the first unloading hopper 7 to adjust its elevation angle. Understandably, in actual use, the unloading direction needs to be adjusted in real time to adapt to the real-time position of the transport vehicle. In this embodiment, the first drive mechanism 8 and the second drive mechanism can respectively drive the first unloading hopper 7 and the second unloading hopper 3 to adjust their horizontal and elevation angles to adapt to different working conditions.

[0080] In some specific embodiments, the first drive mechanism 8 includes a mounting base, a drive motor 801, a driving gear 802, and a driven gear 803; the mounting base is connected to the grain silo; the drive motor 801 is mounted on the mounting base; the driving gear 802 is connected to the output shaft of the drive motor 801; the driven gear 803 meshes with the driving gear 802 and is connected to the first unloading cylinder 7 via a fastener 804, so as to drive the first unloading cylinder 7 to rotate horizontally relative to the grain silo to adjust the horizontal angle. A second drive mechanism is connected to the top of the first unloading cylinder 7, the second drive mechanism including a connecting cylinder 6 and a hydraulic cylinder 4; the first end of the connecting cylinder 6 is hinged to the top of the first unloading cylinder 7, and the second end is fixedly connected to the end of the second unloading cylinder 3 away from the unloading port 2; the hydraulic cylinder 4 is mounted on the first unloading cylinder 7, and the telescopic end of the hydraulic cylinder 4 is connected to the second unloading cylinder 3 so that the telescopic movement of the hydraulic cylinder 4 drives the first unloading cylinder 7 to rotate vertically to adjust the elevation angle. An angle sensor 5 is provided at the hinge position of the connecting cylinder 6 and the first unloading cylinder 7. The angle sensor 5 is used to detect the angle between the second unloading cylinder 3 and the connecting cylinder 6 relative to the first unloading cylinder 7 to determine the elevation angle, so as to monitor the elevation angle in real time for control.

[0081] The auger mechanism 10 is located within the first unloading hopper 7 and the second unloading hopper 3. The auger shaft 11 of the auger mechanism 10 is arranged along the extending direction of the first unloading hopper 7 and the second unloading hopper 3. The auger mechanism 10 is used to transport grain entering the first unloading hopper 7 from the grain silo through the first unloading hopper 7 and the second unloading hopper 3 to the unloading port 2 at the end of the second unloading hopper 3, where it is discharged into the transport vehicle hopper. The PWM duty cycle and rotation speed of the auger mechanism 10 can be controlled in real time to adapt to the safety or efficiency requirements of different working conditions. The photoelectric sensor 12 is located within the second unloading hopper 3 to detect the grain flow rate within the second unloading hopper 3. The photoelectric sensor 12 includes a sensor base 1201 and a sensing element 1202 mounted on the sensor base 1201.

[0082] In a specific embodiment, an industrial camera 1 is also provided at the unloading port 2. The industrial camera 1 includes a camera mounting base 102 installed on the second unloading cylinder 3 and a camera body 101 installed on the camera mounting base 102. The industrial camera 1 is used to acquire real-time images inside the transport truck bed to determine the grain coverage inside the transport truck bed, thereby adaptively adjusting the unloading direction and unloading strategy.

[0083] Example 2

[0084] Combination Figure 6 and Figure 7 This embodiment provides a control method for a combine harvester unloading system as described in Embodiment 1. The control method includes:

[0085] Step S1: In response to the grain silo balance sensor 9 detecting that the grain silo balance has reached a preset threshold, a grain unloading command is triggered.

[0086] Step S2: In response to the unloading command, the action strategy is determined according to the preset position coordinate parameters of the transport hopper. In this embodiment, before responding to the unloading command, the grain bin remaining sensor 9, photoelectric sensor 12, angle sensor 5, first unloading cylinder 7, and second unloading cylinder 3 need to be initialized and self-checked. The angle sensor 5 is calibrated to zero to confirm that the second unloading cylinder 3 is in the initial storage position, parallel to the longitudinal axis of the combine harvester, with an elevation angle of 0°. The photoelectric sensor 12 starts light source detection to confirm that the light path is unobstructed. The grain bin remaining sensor 9 scans the bottom of the grain bin to generate the initial remaining reference value. After the system initialization and self-check operation is passed, the PLC controller (this embodiment uses PLC control, but other control methods with the same function in the prior art can also be used) sends a start signal to the second drive mechanism (hydraulic cylinder 4 in this embodiment), and the auger mechanism 10 enters the standby state.

[0087] Step S3: Rotate the first unloading cylinder 7 and the second unloading cylinder 3 into position according to the action strategy, so that the unloading port 2 is aligned with the center of the transport vehicle bed and start the auger mechanism 10 to unload grain at the initial speed.

[0088] As a specific example, in this embodiment, the rotation method of the first unloading cylinder 7 and the second unloading cylinder 3 is as follows:

[0089] Horizontal rotation: The first drive mechanism 8 drives the first unloading drum 7 to rotate horizontally around the bottom hinge point, and the angle sensor 5 feeds back the horizontal rotation angle data to the PLC controller in real time.

[0090] Angle adjustment: The second drive mechanism pushes the second unloading cylinder 3 to swing upward to the preset angle of 15°, ensuring that the unloading port 2 is aligned with the center of the transport vehicle.

[0091] In this embodiment, the PLC controller uses a PID algorithm to control the opening of the hydraulic proportional valve of the hydraulic cylinder 4 in the second drive mechanism in a closed loop. By controlling the control current of the hydraulic proportional valve, the opening of the hydraulic proportional valve of the hydraulic cylinder 4 can be controlled, thereby dynamically adjusting the hydraulic flow and making the error between the actual rotation angle of the unloading drum and the target angle ≤ ±1°.

[0092] Furthermore, the grain unloading mechanism is activated and operates at an initial speed (500 rpm in this embodiment). The photoelectric sensor 12 detects the grain flow rate in the second unloading drum 3 in real time, calculates the instantaneous flow rate value through the light intensity attenuation rate, and sends the grain flow rate data to the PLC controller.

[0093] Step S4: During the unloading process, based on the grain silo balance detected by the grain silo balance sensor 9, the environmental parameters detected by the pre-arranged environmental sensors, and the position coordinate parameters of the transport vehicle, determine whether it is necessary to enter a specific control mode.

[0094] The purpose of setting a specific control mode in this embodiment is that both the remaining amount of grain in the silo and the working environment will change in real time during the unloading process, which may lead to various situations that could affect the safety of unloading, or relatively safe and energy-saving situations. Therefore, it is necessary to adjust the control strategy to adapt to these possible situations, so as to ensure the continuous, safe and stable operation of unloading.

[0095] In some specific embodiments, the remaining grain storage capacity is preset with a first threshold and a second threshold that increase sequentially; the environmental parameters include wind speed and terrain inclination; the specific control modes include high load mode, energy-saving mode and anti-interference mode.

[0096] If the remaining grain in the grain bin is greater than the second threshold and the position coordinate parameters of the transport vehicle are fixed, the high-load mode is entered.

[0097] If the remaining grain storage capacity is less than the first threshold and the wind speed and terrain inclination are both less than the corresponding thresholds, the energy-saving mode is entered.

[0098] If both the wind speed and the terrain tilt angle are greater than the corresponding threshold, enter the anti-interference mode;

[0099] The priority order is anti-interference mode, high load mode, and energy saving mode.

[0100] As a concrete example, let's illustrate this with some typical optional values:

[0101] If the grain silo capacity is greater than 70% and the position of the transport truck bed is fixed (horizontal coordinate fluctuation ≤ ±0.5m), then it enters high load mode;

[0102] If the remaining grain volume is less than 30%, and the wind speed is less than 5 m / s and the terrain slope is less than 5°, then switch to energy-saving mode.

[0103] If the wind speed is greater than 5 m / s or the terrain slope is greater than 5°, the anti-interference mode will be forcibly activated.

[0104] This is an optional example. The specific threshold can be adaptively adjusted or pre-calibrated according to actual needs. This embodiment does not impose any specific limitations.

[0105] Step S5: If it is necessary to enter a specific control mode, control the auger mechanism 10, the first drive mechanism 8 and the second drive mechanism according to the specific control mode; if it is not necessary to enter a specific control mode, control the auger mechanism 10 in stages according to the grain flow detected by the photoelectric sensor 12.

[0106] In some specific embodiments, the control strategies for each specific control mode and the normal mode when it is not necessary to enter a specific control mode are described in detail below:

[0107] First, in this embodiment, the PWM duty cycle of the auger mechanism 10 is preset with sequentially increasing first, second, and third duty cycles (typical values ​​can be 40%, 70%, and 85%); the rotational speed of the auger mechanism 10 is preset with sequentially increasing first, second, third, fourth, fifth, and sixth rotational speeds (typical values ​​can be 300 rpm, 400 rpm, 500 rpm, 600 rpm, 700 rpm, and 800 rpm); the third rotational speed is used as the initial rotational speed; the grain flow rate is preset with sequentially increasing first and second flow rates (typical values ​​can be 30 kg / s and 80 kg / s).

[0108] When it is determined that a specific control mode needs to be entered:

[0109] The control strategy for the high-load mode includes adjusting the PWM duty cycle of the auger mechanism 10 to the third duty cycle and the rotation speed of the auger mechanism 10 to the sixth rotation speed; controlling the second drive mechanism to adjust the elevation angle of the second unloading cylinder to the corresponding preset value; and controlling the first drive mechanism 8 to keep the unloading port aligned with the center of the transport vehicle hopper. As a specific example, the PWM duty cycle of the auger motor is increased to 85%, and the rotation speed is increased to 800 rpm; the hydraulic cylinder 4 increases the elevation angle of the second unloading cylinder 3 to 30°, and the first drive mechanism 8 finely adjusts the horizontal rotation angle of the first unloading cylinder 7 to ensure that the unloading port 2 is aligned with the center of the transport vehicle hopper.

[0110] The control strategy for the energy-saving mode includes controlling the rotational speed of the auger mechanism 10 within the range between the second and fourth rotational speeds, and keeping the second drive mechanism in a low-power mode. As a specific example, considering selectable typical values: the auger speed is dynamically adjusted to 400–600 rpm; the hydraulic cylinder 4 switches to low-power mode, and the hydraulic proportional valve opening is limited to 50%.

[0111] The control strategy of the anti-interference mode includes enabling overload protection for the motor of the auger mechanism 10, increasing the output torque of the motor from the default value to a preset ratio, controlling the second drive mechanism to lower the elevation angle of the second unloading cylinder to the corresponding preset value; calibrating the horizontal rotation angle of the first unloading cylinder at preset intervals to compensate for the offset caused by wind or slope. As a specific example, combined with typical values: the motor of the auger mechanism 10 is enabled with overload protection, and the output torque is increased by 20%; the elevation angle of the second unloading cylinder 3 is reduced to 10°, and the horizontal rotation angle of the first unloading cylinder 7 is dynamically calibrated every 5 seconds to compensate for the offset caused by wind or slope.

[0112] The mode switching priority is: anti-interference mode > high load mode > energy saving mode, ensuring operational safety as the top priority. Flow data is updated every 0.1 seconds, and the PLC controller dynamically adjusts the speed of the auger mechanism 10 to ensure that the fluctuation range of grain flow is ≤±5%.

[0113] Furthermore, when it is determined that entering a specific control mode is not required:

[0114] If the grain flow rate is greater than the second flow rate, the PWM duty cycle of the auger mechanism 10 motor is adjusted to the first duty cycle, and the speed is adjusted to the first speed.

[0115] If the grain flow rate is greater than the first flow rate and less than the second flow rate, the auger mechanism 10 maintains its current rotation speed.

[0116] If the grain flow rate is less than the first flow rate, the PWM duty cycle of the auger mechanism 10 motor is modulated to the second duty cycle, and the speed is adjusted to the fifth speed.

[0117] As a concrete example, let's illustrate this with some typical optional values:

[0118] The PLC controller executes a graded control strategy based on grain flow rate values, including:

[0119] High flow rate range (≥80kg / s): Reduce the PWM duty cycle of the auger motor to 40% and the speed to 300rpm to prevent blockage.

[0120] Medium flow rate range (30-80 kg / s): Maintain the current rotation speed.

[0121] Low flow rate range (<30kg / s): Increase the duty cycle to 70% and the rotation speed to 700rpm to improve unloading efficiency.

[0122] This embodiment uses a tiered control strategy to maintain grain flow within a safe range, thereby ensuring efficient unloading while preventing blockages. During the unloading process, the grain silo level sensor 9 continuously monitors the grain level in the silo. When the grain silo level drops to a threshold (i.e., 5%), the PLC controller enters the final unloading mode.

[0123] In a specific embodiment, the control method in this embodiment further includes: if the grain flow rate is lower than the preset flow rate lower limit value for a continuous period of time, the rotation speed of the auger mechanism 10 is reduced by a preset ratio at each preset time interval until the rotation speed is reduced to the preset rotation speed lower limit value, and at the same time, the elevation angle of the second unloading drum 3 is adjusted down by a preset angle at each preset time interval until it returns to zero.

[0124] As a concrete example, let's illustrate this with some typical optional values:

[0125] When the photoelectric sensor 12 detects that the grain flow rate has been below 10 kg / s for more than 10 seconds, the PLC controller starts a gradual deceleration program, reducing the speed of the auger mechanism 10 by 10% every 5 seconds until the speed drops to 100 rpm. At the same time, the hydraulic cylinder 4 gradually reduces the elevation angle of the unloading drum 3 (adjusting by 2° each time) to prevent the remaining grain from accumulating due to insufficient gravity.

[0126] In one specific embodiment, the control method further includes:

[0127] If the grain silo balance sensor 9 detects that the grain silo balance is less than the preset lower limit value, and the grain flow is zero and continues for more than the corresponding preset time, a stop signal is sent to the auger mechanism 10.

[0128] In response to the stop signal, the auger mechanism 10 stops operating and controls the first drive mechanism 8 and the second drive mechanism to reset;

[0129] The resetting of the first drive mechanism 8 and the second drive mechanism includes:

[0130] The second drive mechanism is controlled to lower the elevation angle of the second unloading drum 3 at a corresponding preset angular velocity until it reaches the initial zero position;

[0131] The first drive mechanism 8 is controlled to make the horizontal rotation angle of the first unloading drum 7 return to the initial zero position at a corresponding preset angular velocity;

[0132] As a concrete example, let's illustrate this with some typical optional values:

[0133] When the grain silo level sensor 9 detects a level ≤1% and a flow rate of 0 kg / s for 5 seconds, the PLC controller executes a reset command: sending a stop signal to the unloading auger mechanism 10, causing the auger mechanism 10 to completely stop operating. The hydraulic cylinder 4 is then activated, driving the second unloading cylinder 3 to reset in two steps at low speed.

[0134] Specifically, the reset action of the second unloading canister 3 includes:

[0135] Elevation angle reset: Hydraulic cylinder 4 slowly retracts, and the elevation angle of the second unloading cylinder 3 decreases to 0° at a rate of 0.5° / s.

[0136] Horizontal reset: The first drive mechanism 8 rotates in the opposite direction, and the horizontal rotation angle of the first unloading drum 7 returns to the initial storage position at a rate of 5° / s.

[0137] Angle sensor 5 monitors the entire reset process. If the target position is not reached within 10 seconds, the PLC triggers an abnormal alarm (audio and visual alert) and locks the system for manual intervention. After the reset is complete, the PLC controller shuts off the hydraulic system power and enters a low-power standby state.

[0138] Example 3

[0139] This embodiment, based on the control method given in Embodiment 2, further provides a control method that incorporates an image recognition module, as detailed below:

[0140] Specifically, in this embodiment, the industrial camera 1 is fixedly installed on the end face of the second unloading drum 3, located 50-60cm above the unloading port 2, facing downwards into the transport truck bed, and its field of view can completely cover the main area inside the truck bed.

[0141] After the unloading command is initiated, industrial camera 1 adjusts its focus and angle to ensure that the loading area of ​​the truck bed is centered in the frame. The image processing unit loads preset parameters (including truck bed size, height threshold, etc.) and starts real-time video stream analysis.

[0142] Understandably, the industrial camera 1 is connected to the image processing unit, which has a built-in lightweight target recognition model that can process real-time images using deep learning-based image segmentation algorithms to extract the grain coverage in the transport truck bed.

[0143] Furthermore, the image processing unit updates the image recognition results every second and identifies areas in the transport truck hopper with insufficient grain coverage as abnormal areas, sending the center coordinates of these abnormal areas to the PLC controller. Based on this, the PLC controller adjusts the horizontal angle of the first unloading cylinder 7 via the first drive mechanism 8, and then adjusts the elevation angle of the second unloading cylinder 3 via the hydraulic cylinder 4, aligning the unloading port 2 with the area in the transport truck hopper with insufficient grain coverage, thus controlling the unloading direction.

[0144] Understandably, in this embodiment, the PLC controller compares the coordinates of the missing area (or abnormal area) fed back by the image recognition module with the current position of the unloading port 2 of the unloading hopper, and calculates the required horizontal rotation angle difference Δθ and elevation angle adjustment amount Δφ. The PLC controller uses its built-in two-dimensional coordinate conversion model (which has calibrated the correspondence between the transport vehicle's relative coordinate system and the unloading hopper's coordinate system) to convert the image coordinates into the target offset angle and generate real-time control commands.

[0145] If Δθ≠0, the first drive mechanism 8 is controlled to rotate in the forward or reverse direction, driving the first unloading cylinder 7 to rotate around the vertical axis until the horizontal angle deviation is less than the set threshold (i.e., ±1°); at the same time, if Δφ≠0, the elevation angle of the second unloading cylinder 3 is changed by adjusting the cylinder extension length of the hydraulic cylinder 4, ensuring that the unloading port 2 is aligned with the target area in the vertical direction.

[0146] Understandably, throughout the adjustment process, the angle sensor 5 can provide real-time feedback on the current angle data of the second unloading hopper 3, sampling once every 0.1 seconds. The PLC controller continuously corrects the control signal based on the error value, forming a closed-loop control logic.

[0147] To illustrate with a specific example, when the image recognition module detects an uncovered area in the right front region of the truck bed (with the center of the truck bed as the origin, offset coordinates X = +0.8m, Y = +0.5m), the PLC converts this offset into the requirement for the first unloading cylinder 7 to rotate clockwise by approximately 15° and the second unloading cylinder 3 to rise by approximately 5°. Subsequently, it sends corresponding control signals to the drive motor 801 of the first drive mechanism 8 and the hydraulic cylinder 4 of the second drive mechanism, thereby achieving automatic correction of the unloading direction and precise alignment of the target area.

[0148] Understandably, in order to ensure the continuity of grain unloading, the control command maintains the operation of the auger mechanism 10 while adjusting the angle, so as to avoid interruption of grain unloading.

[0149] Furthermore, the present invention provides a system protection mechanism: if the horizontal rotation angle of the first unloading hopper 7 or the elevation angle of the second unloading hopper 3 deviates from the corresponding preset threshold for more than a preset time relative to the target angle, an action stop command is triggered to maintain the current state and ensure structural safety.

[0150] As a specific example, combined with optional typical values, if the first unloading hopper 7 and the second unloading hopper 3 deviate from the target angle by less than the set threshold within 3 consecutive seconds, the control action stops and the system maintains the current state to prevent unnecessary angle jitter.

[0151] Furthermore, this embodiment also provides a fault handling mechanism. Based on the image recognition result and the grain flow information detected by the photoelectric sensor 12, if the industrial camera 1 reports that the grain coverage area in the transport hopper is empty but the photoelectric sensor 12 still detects a high grain flow, the system issues a prompt alarm requiring manual verification of the industrial camera 1 or cleaning of the lens.

[0152] It is readily understood that those skilled in the art can combine, split, or reorganize the embodiments provided in this application to obtain other embodiments, all of which do not exceed the protection scope of this application.

[0153] The present invention and its embodiments have been described above illustratively. This description is not restrictive, and the embodiments shown are only part of the embodiments of the present invention. The actual structure is not limited thereto. Therefore, if those skilled in the art are inspired by this description and design similar structures and embodiments without departing from the spirit of the present invention, such designs should fall within the protection scope of the present invention.

Claims

1. A control method for a combine harvester unloading system, characterized in that, The combine harvester unloading system includes: A grain warehouse, on which a grain level sensor is installed; The first unloading hopper is connected to the grain silo and can be driven by the first driving mechanism to rotate horizontally relative to the grain silo to adjust the horizontal angle. The second unloading hopper is connected to the first unloading hopper and can be driven by the second drive mechanism to rotate vertically relative to the first unloading hopper to adjust the elevation angle. An auger mechanism is provided inside the first unloading drum and the second unloading drum. The auger mechanism is used to transport the grain that enters the first unloading drum from the grain silo through the first unloading drum and the second unloading drum to the unloading port at the end of the second unloading drum and unload it into the transport vehicle hopper. A photoelectric sensor is installed inside the second unloading hopper to detect the grain flow rate inside the second unloading hopper; The control method includes: In response to the grain silo balance sensor detecting that the grain silo balance has reached a preset threshold, a grain unloading command is triggered. In response to the unloading command, the action strategy is determined based on the preset position coordinate parameters of the transport vehicle bed; According to the action strategy, the first and second unloading cylinders are rotated into position so that the unloading port is aligned with the center of the transport vehicle bed and the auger mechanism is started to unload the grain at the initial speed. During the unloading process, based on the grain silo balance detected by the grain silo balance sensor, the environmental parameters detected by the pre-positioned environmental sensors, and the position coordinate parameters of the transport vehicle bed, it is determined whether it is necessary to enter a specific control mode. If a specific control mode needs to be entered, the auger mechanism, the first drive mechanism, and the second drive mechanism shall be controlled according to the specific control mode. If it is not necessary to enter a specific control mode, the auger mechanism can be controlled in stages according to the grain flow detected by the photoelectric sensor; The grain storage capacity is pre-set with a first threshold and a second threshold that increase sequentially; the environmental parameters include wind speed and terrain inclination. The step of determining whether to enter a specific control mode includes: If the remaining grain in the grain bin is greater than the second threshold and the position coordinate parameters of the transport vehicle are fixed, the high-load mode is entered. If the remaining grain storage capacity is less than the first threshold and the wind speed and terrain inclination are both less than the corresponding thresholds, the energy-saving mode is entered. If both the wind speed and the terrain tilt angle are greater than the corresponding threshold, enter the anti-interference mode; The priority order is as follows: anti-interference mode, high load mode, and energy-saving mode. The PWM duty cycle of the auger mechanism motor is preset with a first duty cycle, a second duty cycle, and a third duty cycle that increase sequentially. The rotational speed of the auger mechanism is preset to have a first rotational speed, a second rotational speed, a third rotational speed, a fourth rotational speed, a fifth rotational speed, and a sixth rotational speed that increase sequentially; the third rotational speed is used as the initial rotational speed. The grain flow rate is preset with a first flow rate and a second flow rate that increase sequentially. When it is determined that a specific control mode needs to be entered: The control strategy for the high-load mode includes adjusting the PWM duty cycle of the auger mechanism to the third duty cycle and the rotation speed of the auger mechanism to the sixth rotation speed; controlling the second drive mechanism to adjust the elevation angle of the second unloading cylinder to the corresponding preset value; and controlling the first drive mechanism to keep the unloading port aligned with the center of the transport vehicle hopper. The control strategy of the energy-saving mode includes controlling the rotation speed of the auger mechanism within the range between the second and fourth rotation speeds, and keeping the second drive mechanism in a low-power mode. The control strategy of the anti-interference mode includes enabling overload protection for the motor of the auger mechanism, increasing the output torque of the motor from the default value to a preset ratio, controlling the second drive mechanism to lower the elevation angle of the second unloading cylinder to the corresponding preset value, and calibrating the horizontal rotation angle of the first unloading cylinder at preset intervals to compensate for the offset caused by wind or slope. When it is determined that entering a specific control mode is not necessary: If the grain flow rate is greater than the second flow rate, the PWM duty cycle of the auger mechanism motor is adjusted to the first duty cycle, and the speed is adjusted to the first speed. If the grain flow rate is greater than the first flow rate and less than the second flow rate, the auger mechanism maintains its current rotation speed. If the grain flow rate is less than the first flow rate, the PWM duty cycle of the auger mechanism motor is modulated to the second duty cycle, and the speed is adjusted to the fifth speed.

2. The control method for the combine harvester unloading system according to claim 1, characterized in that, The bottom end of the first unloading hopper is connected to a first driving mechanism, which includes: Mounting base, connected to the grain silo; A drive motor is mounted on the mounting base; The drive gear is connected to the output shaft of the drive motor; The driven gear meshes with the driving gear and is connected to the first unloading cylinder by fasteners, so as to drive the first unloading cylinder to rotate horizontally relative to the grain bin and adjust the horizontal angle.

3. The control method for the combine harvester unloading system according to claim 1, characterized in that, The top of the first unloading hopper is connected to a second driving mechanism, which includes: The connecting cylinder has its first end hinged to the top of the first unloading cylinder and its second end fixedly connected to the end of the second unloading cylinder away from the unloading port. A hydraulic cylinder is installed on the first unloading cylinder. The telescopic end of the hydraulic cylinder is connected to the second unloading cylinder so that the second unloading cylinder can be rotated vertically to adjust the elevation angle through the telescopic movement of the hydraulic cylinder.

4. The control method for the combine harvester unloading system according to claim 3, characterized in that, An angle sensor is provided at the hinge position of the connecting cylinder and the first unloading cylinder. The angle sensor is used to detect the angle between the second unloading cylinder and the connecting cylinder relative to the first unloading cylinder to determine the elevation angle.

5. The control method for the combine harvester unloading system according to claim 1, characterized in that, Also includes: An industrial camera is installed at the unloading port and is used to acquire real-time images of the inside of the transport vehicle.

6. The control method for the combine harvester unloading system according to claim 1, characterized in that, The control method further includes: If the grain flow rate is lower than the preset flow rate lower limit for a continuous period of time, the rotation speed of the auger mechanism will be reduced by a preset percentage at each preset time interval until the rotation speed is reduced to the preset rotation speed lower limit. At the same time, the elevation angle of the second unloading hopper will be adjusted down by a preset angle at each preset time interval until it returns to zero.

7. The control method for the combine harvester unloading system according to claim 1, characterized in that, The control method further includes: If the grain silo balance sensor detects that the grain silo balance is less than the preset lower limit value, and the grain flow is zero and continues for more than the corresponding preset time, a stop signal is sent to the auger mechanism. In response to the stop signal, the auger mechanism stops operating and controls the first drive mechanism and the second drive mechanism to reset; The resetting of the first and second drive mechanisms includes: The second drive mechanism is controlled to lower the elevation angle of the second unloading hopper at a corresponding preset angular velocity until it reaches the initial zero position; The first drive mechanism is controlled to return the horizontal rotation angle of the first unloading hopper to the initial zero position at a corresponding preset angular velocity. The control method further includes: If the horizontal rotation angle of the first unloading hopper or the elevation angle of the second unloading hopper deviates from the corresponding preset threshold for more than a preset time relative to the target angle, an action stop command is triggered, and the current state is maintained and stopped. The control method further includes: If the grain-covered area in the real-time image of the transport truck bed captured by the industrial camera at the unloading port is empty, and the grain flow detected by the photoelectric sensor is above the corresponding preset threshold, an alarm command will be triggered to prompt manual verification of the industrial camera or cleaning of the lens. The control method further includes: Based on real-time image processing of the transport truck bed captured by industrial cameras, abnormal areas with insufficient grain coverage in the transport truck bed were identified. Based on the center coordinates of the abnormal area, adjust the rotation angles of the first and second unloading cylinders so that the unloading port is aligned with the abnormal area for unloading.

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