Method for controlling REEL height

Abstract

A control system is provided for a combine header, which controls a position of a reel relative to a header and to a method for controlling a height of the reel relative to a crop canopy to maintain a targeted, preset reel engagement therewith. With this control system, a reel control system thereof can operate to automatically adjust the reel height relative to the crop canopy as well as the ground during cutting of field crops. The reel control system can automatically adjust the reel height during changes to the canopy height by instantaneously processing the sensor data, which can be averaged over a period of time. A target reel engagement can be preset to bias the reel height relative to higher or lower canopy ranges by a level of aggressiveness (or bias) of the reel engagement target to tune the performance of the reel control for downed crop conditions.

Description

METHOD FOR CONTROLLING REEL HEIGHTFIELD OF THE INVENTION

[0001] The invention relates to a control system for an agricultural implement, and preferably, to a combine having a header and reel and methods for controlling the reel to control reel height relative to a crop canopy.BACKGROUND OF THE INVENTION

[0002] Combines for harvesting a variety of crops from a field are generally known in the art. Combines include headers mounted in front of a feeder house. The headers include a cutter bar assembly to cut crop material from the field, and a draper belt assembly positioned behind the cutter bar assembly to transport crop material into the feeder house. Further, a reel may be provided above the header and the cutter bar to help sweep crop into the header for cutting.

[0003] A variety of hydraulic cylinders may be used to adjust combine components such as the height of the cutter bar assembly. For example, a gauge wheel or contour wheel cylinder may extend or retract gauge wheels on the header to adjust the height of the cutter bar assembly when cutting above the ground. Similarly, a skid shoe cylinder may be provided to extend or retract skid shoes on the header to adjust the height of the cutter bar assembly when cutting close to the ground. A header tilt cylinder and / or a faceplate cylinder also may control the pitch of the header relative to the ground during the cutting action.

[0004] In known header designs such as a flex header, the header may comprise header segments that can articulate and follow ground contours, wherein an operator may use the gauge wheels or contour wheels as a means to control the height of a flex header while allowing it to follow the field topography, similar to when it is cutting on the ground. When determining appropriate cut height, an operator determines the length of stubble desired and adjusts the height of the gauge wheels.

[0005] Some header configurations monitor the ground and the height of the cutter bar assembly above the ground to thereby define the constant stubble height. In one example disclosed in US20220279719A1, a header height control is provided for a harvesting head, wherein this known system controls the header relative to the ground using sensors and hydraulic lift and flex cylinders to control the cut height.

[0006] Further, such headers used for harvesting grains and oilseeds typically include the aforementioned reel. The purpose of the reel is to positively engage crop to direct crop flow over thecutter bar of a harvest header towards the side drapers or auger in order to be conveyed laterally towards the center feed area where the combine harvester receives crop material for further processing. The reel height needs to be adjusted when the height or position of the crop being harvested changes, requiring frequent operator input. If the reel height is not adjusted properly it can result in poor crop flow, which can plug harvesters and delay or halt the harvest process. Adverse crop conditions such as downed (lodged) crop can influence the strategy required for adjusting the reel position.

[0007] It is an object of the invention to provide a header having an improved reel and methods for controlling the reel height to provide more consistent reel engagement with the crop.SUMMARY OF THE INVENTION

[0008] The improved header and header control system comprises a reel control system that allows for automatic adjustment of the height of the reel. In a typical header design, adjustment of the reel is the most frequently adjusted system of the header. However, such adjustment typically can be made by the operator manually using system controls, but this can require frequent operator adjustments. The improved control system automates adjustment of the reel height, which reduces the need for operators to interact with the reel control system and therefore improves the usability of the reel during field operations.

[0009] The present invention includes at least one and preferably a series of sensors that are configured to sense the distance to the crop canopy to calculate the crop height, as well as sense the distance to the ground. The sensors may be located across the width of the header in front of the reel such that they can sense canopy distance and ground distance ahead of the reel as the combine moves through the field. The operator defines a target reel engagement with the crop (i.e. distance the reel protrudes below the top of the crop canopy) and the reel control system works to maintain the reel height such that the reel engagement is equal to the operator defined setpoint. This provides for automatic control of the reel height, which reduces the need for operator input resulting in more optimal crop feeding performance and less down time.

[0010] These sensors attached to the header also permit determination of the crop height and the distance to the ground from the cutter bar assembly. In addition to controlling the reel height, the header control system may also be operated to vary the position of the gauge wheels and cutter bar assembly supported thereby to control the position of the cut height off of the ground, which may be based upon inputs from the operator. With the use of appropriate sensors, the header control system can operate to automatically adjust the gauge wheel position relative to thecrop canopy as well as the ground wherein the reel control system can automatically adjust the reel height during these changes to the cut height.

[0011] This inventive header control system and its reel control system do not create a field map of the measured values. Rather, it uses instantaneous values captured by the sensor(s), which are averaged over a period of time. Adjustments are made at the end of each of these periods of time.

[0012] Further, this inventive control system preferably does not adjust the reel position based on harvester throughput. Rather, this reel control system focuses on a consistent reel engagement with the crop, which is believed to optimize throughput in all situations. The reel engagement value may be different depending on crop type.

[0013] Further, a level of aggressiveness (or bias) of the reel engagement target is defined in this invention. This setting allows machine operators to tune the performance of the reel control for downed crop conditions. This is important since the crop height and crop condition can vary across the width of the header. For example, standing crop may be present across portions of the header while lodged crop may be encountered at other locations along the header. In such situations, the reel control system can incorporate an aggressiveness setting that biases a sensor averaging algorithm towards shorter crop on the one hand or taller crop on the other hand depending upon the aggressiveness value.

[0014] In another aspect of the invention, in lower density crop conditions, the sensor(s) may sometimes miss crop canopy and measure the ground and crop canopy as the same value. This results in the reel lowering fully which would not be the desired function. A method of filtering the sensor signal for sparse or low density crop conditions may be incorporated into the reel control system to improve function in those conditions.

[0015] Other objects and purposes of the invention, and variations thereof, will be apparent upon reading the following specification and inspecting the accompanying drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure l is a front perspective view of an agricultural implement configured as a harvester combine having a header and reel.

[0017] Figure 2 is an enlarged perspective view of the header and reel thereof.

[0018] Figure 3 is a partial plan view of the combine with the header and reel.

[0019] Figure 4 is a diagrammatic side view of the inventive header and reel illustrating the reel at a first height, which is elevated for a higher crop canopy.

[0020] Figure 5 is a diagrammatic side view of the inventive header and reel illustrating the reel at a second height, which is dropped for a lower crop canopy.

[0021] Figure 6 is a diagrammatic front view of the header and reel of the combine illustrating a variable crop height relative to a calculated average crop height.

[0022] Figure 7 is a diagrammatic front view of the header and reel of the combine illustrating the variable crop height relative to aggressiveness levels relative to an aggressiveness range between 0-10.

[0023] Figure 8 is a side view of the header and reel on the combine in relation to a crop canopy and multiple geometric variables for the header and reel.

[0024] Figure 9 is an enlarged partial side view of the header attachment as shown in Figure 8 and the geometric variables in this region.

[0025] Figure 10 is an enlarged partial side view of the reel supported on the header as shown in Figure 8 and the geometric variables in this region.

[0026] Figure 11 is an enlarged partial side view of the reel and a sensor configuration as shown in Figure 8 and the geometric variables in this region.

[0027] Figure 12 is a flowchart showing the operational process for operating the inventive header and reel to provide reel height control.

[0028] Figure 13 is a flowchart showing the operational process for filtering the sensors.

[0029] Figure 14 is a flowchart showing the operational process for sensor pitch correction.

[0030] Certain terminology will be used in the following description for convenience and reference only, and will not be limiting. For example, the words "upwardly", "downwardly", "rightwardly" and "leftwardly" will refer to directions in the drawings to which reference is made. The words "inwardly" and "outwardly" will refer to directions toward and away from, respectively, the geometric center of the arrangement and designated parts thereof. Said terminology will include the words specifically mentioned, derivatives thereof, and words of similar import.DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0031] Figure 1 illustrates a combine harvester i.e., combine 10 according to embodiments of the present invention. The combine 10 includes a header 12 mounted on a feeder house 14. The header 12 includes a header frame 13 and a cutter bar assembly 16 operatively extending across a front portion of the header 12 to cut crop material from the field. A draper assembly typically ispositioned behind the cutter bar assembly 16 to transport the crop material into the feeder house 14.

[0032] In the preferred configuration such as the embodiment of Figures 1-4, the header 12 is supported close to the ground 17 (see Figure 4) such that the height of the cutter bar assembly 16 can be varied to cut crop close to the ground 17 and to increase the cut height according to ground and crop conditions. The header 12 is attached to the feeder house 14 by an adapter 18, which attaches the header to the feeder house 14. The adapter 18 is provided to control the feeding of material into the feeder house 14 and to provide a lifting force to the header 12 to carry it forwardly on the front of the feeder house 14. The adapter 18 includes a float suspension using springs or a cylinder system allowing the header 12 to float upwardly and downwardly relative to the feeder house 14.

[0033] The header 12 may be of a conventional construction well known to a person skilled in this art and the major components include the cutter bar assembly 16 having a cutter bar 19 for cutting standing crop and a crop transport device defined by the draper assembly for transporting the standing crop inwardly from ends of the header 12 to a collection location for feeding to the combine harvester 10 through the feeder house 14. The connection between the adapter 18 and the header 12 may include the float or suspension system 20 for carrying the header 12 on the adapter 18. As is well known, the float or suspension system 20 allows pivotal movement of the header 12 relative to the adapter 18 as well as vertical floating movement of the header 12.

[0034] Referring to Figure 4, the header 12 can run in contact with the ground 17 so that part of the weight is carried on the float system 20 and part applies a ground force. In the preferred configuration, a gauge wheel or contour wheel 23 shown in Figure 4 is pivotably connected to the header 12 for ground following contact. A typical header 12 would have a plurality of such gauge wheels 23. The gauge wheel 23 includes a wheel 24 rotatably connected to a pivot arm 25. The pivot arm 25 is pivotably connected to the header 12 and a hydraulic gauge wheel cylinder may be used to extend and retract the gauge wheel 23. In the extended position, the gauge wheel 23 follows the ground 17 and supports the header 12 when cutting at a set cut height CT above ground 17. Extension or retraction of the gauge wheel 23 can be performed to raise and lower the cut height CT shown in Figure 4. The leading edge of the cutter bar assembly 16 includes the cutter bar 19 to perform cutting of the crop, wherein the cut portion of the crop moves through the header 12 to the feeder house 14, while the remaining crop portion from the cut height CT to ground 17 defines stubble that remains in the field after harvesting. The header 12 may also be adjustable to adjust the pitch thereof.

[0035] Further, the header 12 may be used for harvesting grains and oilseeds and other crops and the inventive header 12 further includes a reel assembly 27 having one or more crop pick-up reels 28. The purpose of a reel 28 is to positively engage crop to direct crop flow over the cutter bar 19 of the header 12, wherein the cut crop flows towards the side drapers or auger in order to be conveyed laterally towards the center feed area where the combine harvester receives crop material for further feeding through the feeder house 14.

[0036] Referring further to Figures 2-3, one or more of the crop pick-up reels 28 are positioned generally above the front portion of the header 12 for engaging the crops to be harvested. The cutter bar assembly 16 operatively extends across the front portion of the header frame 12 between the ends thereof for cutting the crops as referenced above. During harvesting, the crop pickup reels 28 are typically positioned close to the cutter bar assembly 16 without contacting the cutter bar assembly 16 to facilitate optimal harvesting efficiency of the header 12.

[0037] In some embodiments, the cutter bar assembly 16 is correspondingly flexible with center and side wing sections of the header 12 for contouring to the field. One such configuration of the cutter bar assembly 16 and header 12 is described in U.S. Patent No. 10,462,968, the disclosure of which is hereby incorporated by reference in its entirety.

[0038] Referring again to Figures 1-3, the header 12 includes a plurality of reel arms 29 disposed adjacent to each end of the crop pick-up reels 28 for supporting these crop pick-up reels 28 on the header frame 13. Each crop pick-up reel 28 is rotatably supported by respective reel support arms 29. The reel support arms 29 are pivotable on the header frame 13 upwardly and downwardly via a hydraulic system to vertically position the crop pick-up reels 28 relative to the cutter bar assembly 16 for optimally engaging the crops, as is known in the art. It is to be appreciated that the header 12 may ultimately include any number or arrangement of reel support arms 29 and crop pickup reels 28 to correspond to the number of sections on the header 12 without varying the scope of the invention. While the following discussion will focus on one such reel 28, it will be understood the description is applicable to each reel 28.

[0039] In more detail, the reel 28 is mounted over the cutter bar 19 on reel arms 29 by which the height of the reel 28 can be changed to change the spacing between reel bats of the reel 28 and the cutter bar 19. The reel 28 can also include a slide connection 30 (Figure 3) so that it can slide forwardly and rearwardly on the reel arms 29 so as to change the fore and aft position of the reel 28 relative to the cutter bar 19. These movements are actuated by control cylinders or by other means which allow them to be adjusted by a reel control system of the present invention.

[0040] As mentioned, the reel assembly 27 may comprise a plurality of reels 28 arranged side by side and carried on respective reel arms 29 that may be configured to allow independent adjustment of the plural reels 28. The independent adjustment can be in relation to one or more of height and forward and aft position including other known adjustment options as required. This independent adjustment can thus be used when the crop is in different conditions of height and / or lodgment across the width of the header 12.

[0041] For example, as shown in Figure 4, the combine 10 is shown relative to a standing crop extending along the expanse of ground 17 in front of combine 10. The top of the crop generally defines a crop canopy CC that is engaged by each reel 28. While the crop canopy CC may have a consistent height, more realistically, the crop canopy CC varies in height so that it has a crop height CH that is higher in some sections CHI and lower in other sections CH2. When the reel 28 engages the crop canopy CC with the higher crop height CHI, the reel 28 is in the elevated position shown in Figure 4. As noted, the elevation of the reel 28 can be raised or lowered, wherein the reel 28 is lowered to the elevation of Figure 4 when engaging the lower crop height CH2.

[0042] In Figures 4 and 5, the reel 28 engages the upper portion of the crop canopy CC and the extent of depth in the crop canopy CC is referenced as the reel engagement RE in these figures. As can be seen, the reel engagement RE is the vertical amount that a lower portion of the reel 28 engages or sweeps through the upper portion of the crop canopy CC. The reel height RH is shown in reference to an angle between the reel arm 29 and the header 12, which thereby defines the upward distance between the reel 28 and the ground 17. To adjust the reel height RH, the reel arm 29 is swingable upwardly and downwardly about a pivoted end through a pivot connection 31 between the reel arm 29 and the header frame 13 or other structure of the header 12. Where the reel height RH is defined in terms of the angular relation between the reel arm 29 and header frame 13, Figure 4 shows the reel 28 at a 70% reel height RH while Figure 5 shows the reel 28 at a 15% reel height RH with the reel height RH being adjustable through a reel height range of 0% and 100%. The total range of the reel height RH may vary depending upon the configuration of the header 12 and reel assembly 27.

[0043] Further as to Figures 1-4, the improved header 12 operates by a header control system that in many respects is known and does not require a detailed discussion herein. The invention relates to an improved header control system comprising a reel control system that allows for automatic adjustment of the height of the reel assembly 27 and the reels 28 thereof. The improved reel control system automates adjustment of the reel height RH, which reduces theneed for operators to interact with the reel control system, and therefore improves the usability of the reel assembly 27 during field operations.

[0044] The reel control system of the present invention includes at least one and preferably a series of sensors 35 that are configured to sense a canopy distance CD to the crop canopy CC to calculate the crop height CH, as well as sense the ground distance GD to the ground. The sensors 35 are mounted on sensor supports or arms 36, which may be extensions of the reel arms 29. As such, the sensors 35 may be located across the width of the header 12 in front of the reel 28 such that they can sense canopy distance CD and ground distance GD ahead of the reel 28 as the combine 10 moves through the field. As will be described further herein, the operator defines a target reel engagement with the crop (i.e. distance the reel 28 protrudes below the top of the crop canopy CC) and the inventive reel control system processes the sensor data and operates to maintain the reel height RH such that the reel engagement RE is equal to the operator defined setpoint. This provides for automatic control of the reel height RH, which reduces if not eliminates the need for operator input and results in more optimal crop feeding performance and less down time.

[0045] The sensors 35 attached to the header 12 also permit determination of the crop height CH and the distance to the ground 17 from the cutter bar assembly 16. In addition to controlling the reel height RH, the header control system may also be operated in conjunction with the reel control system to vary the position of the gauge wheels 20 and cutter bar assembly 16 supported thereby to control the position of the cut height CT off of the ground, which may be based upon inputs from the operator. With the use of appropriate types of sensors 35, the header control system and its reel control system can operate to automatically adjust the gauge wheel position relative to the crop canopy CC as well as the ground 17. The reel control system can automatically adjust the reel height RH during and in response to these changes to the cut height CT, and the reel height RH and cut height CT can be adjusted independent of each other. For example, in some conditions, the cut height CT may be raised as desired and the reel height RH can be lowered to maintain or increase the reel engagement RE as the cut height CT is raised.

[0046] The sensors 35 may comprise radar sensors that continuously or intermittently sense and monitor the crop canopy CC and crop distance CD and the ground location and ground distance GD, which are typically sensed and monitored simultaneously so that the header and reel control systems can determine the crop height CH. The sensors 35 also may be LiDAR or ultrasonic sensors or other appropriate sensors or sensing means such as a vision system, which can sense or detect the ground elevation and crop height CH even when crops are fully developed. Asdescribed herein, the one or more sensors 35 would reference or detect the crop canopy CC and the ground 17 and determine the canopy distance CD and the ground distance GD from the sensors 35 to the ground 17, wherein these sensors 35 may each have a single sensor module or may have multiple sensing modules that define a single sensor 35.

[0047] In Figures 5 and 6, the header 12 is shown with three reels 28 supported by four reel arms 29. As noted, each reel arm 29 includes a sensor 35 on the sensor support 36 extending forwardly therefrom. In the illustrated configuration, four sensors 35 are provided although the number of sensors 35 can be increased or decreased depending upon the configuration of the header 12 and reel assembly. For example, in some headers 12, there may be two reels 28 and three reel arms 29 with three sensors 35.

[0048] As mentioned, the sensors 35 detect two values, namely the canopy distance CD and ground distance GD. Referring to Figures 4 and 5, the sensor 35 generally projects a sensor beam or signal in a sensor cone SC of about 6 degrees of angular width along a cone axis CA. The cone axis CA preferably projects forwardly and downwardly and the sensor cone generates return signals from the crop canopy CC and ground 17 that are used to determine the crop distance CD and ground distance GD. The crop canopy CC may generate return signals through a first cone width defined by the area of the sensor cone SC at the crop canopy CC while the ground 17 may generate return signals through a second cone width defined by the area of the sensor cone SC at the ground 17, wherein the second cone width would be wider than the first cone width. The angle of projection of the sensor cone based upon the cone axis CA may be at a first angle relative to a vertical reference line (Figure 4) and at a second angle when the reel 28 is lowered (Figure 5). As described below, the changes in the angle or projection might be compensated for through an algorithm performed by the reel control system or might be compensated for mechanically by adjustment of the angle of the sensors 35 as the reel position is adjusted.

[0049] Preferably, the sensors 35 are spread across the width of the header 12 as seen in Figures 5 and 6 with at least one sensor 35 on each opposite header end 38 and one or more sensors 35 located intermediately between the header ends 38. As such, the sensors 35 can generate sensor data indicating crop distance CD and ground distance GD at laterally spaced locations along the lateral width of the header 12. Preferably, the sensors 35 provide respective streams of sensor data that can indicate crop conditions at selected, spaced-apart locations along the lateral width of the header 12. Typically, it is not necessary to detect the crop conditions along the entire width of the header 12 although this might be implemented if desired through the use ofadditional sensors or use of different types of sensors having a wider sensor cone or sensing zone that spans a greater lateral width in front of the header 12.

[0050] In more detail as to Figure 6, the crop canopy CC is diagrammatically shown as having varying heights. In one respect, the crop canopy CC may primarily have a fully grown crop height CHI in the majority of the field wherein the crop height CHI is relatively consistent and spans most of the field being harvested. At the endmost measurement points MP1, the sensors 35 may detect the crop distance CD (Figure 4) so that the reel control system detects the full crop height CHI. However, in portions of the field, the crop may become lodged or at least partially lodged so that the height of the crop canopy CC is reduced. For example, at measurement point MP2, a partially lodged crop canopy CC is detected by the respective sensor 35 and a reduced crop height CH2 is identified. While there is a fully lodged section of crop having a minimal crop height of CH3, the sensors 35 may or may not identify this lodged crop section. Rather, at measurement point MP3, the crop height CH4 may be identified even though the height is almost the full crop height CHI. At the least, the sensors 35 detect at least one reduced-height crop section, which indicates that the reel 28 and its reel engagement RE would be too high to engage any of the partially lodged crop height CH2, much less the lodged crop height CH3. To address this scenario, the improved reel control system may generate an average crop height CHavg so that the sensors 35 are able to detect deviations in the height of the crop canopy CC to some degree.

[0051] The average crop height CHavg can then be used by the reel control system to at least identify that crop height variations have occurred, and if so, the reel control system can automatically adjust the height of the reels 28 based upon the average crop height CHavg being detected to maintain a target reel engagement RE input by the operator. The height of the reels 28 may be raised and lowered individually and independent of each other or may be raised and lowered together in unison. As will be described further herein, the operator defines a target reel engagement RE with the crop (i.e. distance the reel protrudes below the top of the crop canopy) and the reel control system works to maintain the reel height RH such that the reel engagement RE is equal to the operator defined setpoint. This provides for automatic control of the reel height RH, which reduces the need for operator input resulting in more optimal crop feeding performance and less down time.

[0052] In more detail, the reel control system uses instantaneous values captured by the sensor(s) 35, which are averaged over a period of time to determine the average crop height CHavg. If desired, adjustments to the reel height RHcan be made at the end of individual periods of time.

[0053] Unlike other reel configurations, the reel control system of the present invention does not adjust the reel position based on harvester throughput. Rather, this invention focuses on maintaining a consistent reel engagement RE with the crop as that is believed to be more important for optimizing throughput in all situations. The reel engagement value may be different depending on crop type. As the combine 10 moves through a crop with a variable height crop canopy CC, the average of the crop height CHavg may be monitored and the reel height RH automatically adjusted to maintain consistent reel engagement RE based upon the CHavg. If the CHavg increases or is near full height, the reel height may increase or be maintained at a higher elevation such as seen in Figure 4, and if the CHavg decreases such as seen in Figure 5, the reel height may decrease to maintain the set reel engagement RE with the lower height crop.

[0054] In another aspect of the present invention, in lower density crop conditions, the sensor(s) 35 may sometimes miss crop canopy and measure the ground 17 and crop canopy CC as the same value. This results in the reel 28 lowering fully which would not be the desired function. Therefore, the reel control system may comprise a method of filtering the sensor signals for sparse or low density crop conditions to improve function in those conditions.

[0055] With respect to Figure 7, this figure illustrates another inventive feature wherein the variable height of the crop canopy CC can be addressed and overcome by incorporating an aggressiveness feature to the reel control system. In further detail, a level of aggressiveness (or bias) may be associated with the setpoint for the reel engagement RE so that an operator may set both a target reel engagement and an aggressiveness level. The aggressiveness setting allows machine operators to tune the performance of the reel control for downed crop conditions. This is important as crop height and condition can vary across the width of the header 12. Additionally, the header control system and its real control system utilize the aggressiveness setting to bias the sensor averaging algorithm towards shorter crop on the one hand or taller crop on the other hand depending upon the aggressiveness value.

[0056] In Figure 7, a reel engagement target may be set and the actual reel engagement RE may be controlled based upon an aggressiveness setting AGGR between the range of 0 to 10. At an aggressiveness setting AGGR of 0, the reel engagement RE would be biased toward the highest detected height for the crop canopy CC such as the crop heights CHI. At an aggressiveness setting AGGR of 10, the reel engagement RE would be biased toward the lowest detected height for the crop canopy CC such as the crop height CH2. In other words, at AGGR 0, the set reel engagement RE would be based upon the crop canopy CC at height CHI, so that the reel 28would primarily engage the crop having height CHI, which may position the reel 28 above the crop portions having lower crop heights CH3 and CH4. At AGGR 10, the set RE would be based upon the crop canopy CC at height CH3, so that the reel 28 would engage the crop height CH3 with a reel engagement of the set RE while the reels 28 would engage a higher amount of higher crop CHI and engage a lower amount of the lower crop CH4. Potentially, the reel 28 might even sweep above the lower crop CH4 so that there is no reel engagement for this lodged crop.

[0057] In practice, the operator might determine that the header 12 is able to suitably harvest the lodged crop with low crop height CH4 even when the reel 28 is above the lodged crop. In such a scenario, the operator may have preset the aggressiveness setting, and may decide to leave the aggressiveness setting unchanged when encountering lodged crop. However, if the lodged crop is not suitably harvested, the operator may elect to increase the aggressiveness setting AGGR to lower the reels 28 deeper into the crop canopy CC to increase the reel engagement amount with the partially lodged and / or the lodged crop and thereby improve harvesting of the lodged crop.

[0058] To operate the header 12 to automatically adjust the reel height and make this adjustment based upon an aggressiveness setting, the header 12 may include adjustment mechanisms that may vary and adjust the geometry of the mechanisms on the header 12. Figure 8 illustrates the general configuration of the combine 10 with the header 12 supported on the gauge wheel 23. The header 12 includes the reel arm 29 pivotally connected to the header 12 at pivot connection 31, wherein the reel 28 is rotatably mounted on the reel arm 29 and is slidable fore and aft by slide connection 30. As noted above, the sensor support 36 extends forwardly and upwardly from the reel arm 29 and has one or more sensors 35 mounted thereon. The sensors 35 detect the crop canopy CC and ground 17 through an emitted sensor beam having the beam axis CA. As these various components move during combine operation and reel adjustment, the geometric positions change, and the header control system may monitor the geometric variables to compensate for operational movement and accurately use the sensor data indicating the crop distance CD and ground distance GD to thereby determine and monitor the crop height CH.

[0059] In this regard, Figures 8-11 diagrammatically shows some of the different variables for the operating geometry. As shown in Figures 8 and 9, the combine 10 typically has a combine pitch CP relative to ground 17 that may be monitored. The operating system may monitor this pitch CP of the combine / harvester or the cab thereof. Since the header 12 can be raised and lowered by the gauge wheels 23, the cutter bar 19 can be raised and lowered accordingly. As mentioned, the cutter bar assembly 16 and header 12 may be formed as a single unit or frommultiple articulating sections. The control system may monitor the header pitch HP relative to a gravity reference plane or other reference point.

[0060] Referring further to Figures 8 and 10, the sensor supports 36 are configured to extend forwardly of the reel 28 and reel supports 29 to detect the crop canopy CC and ground 17 ahead of the combine 10 as it travels over a field. Since the reel support arm 29 is typically adjustable, the combine control system may monitor the reel arm pitch RAP.

[0061] Next as to Figures 8 and 11, the header 12 uses the sensors 35 on the sensor supports 36 to detect the crop canopy CC and ground 17 to determine and monitor the crop distance CD and ground distance GD, wherein the angle of the sensor cone axis CA of sensors 35 as well as the sensor supports 36 vary as the reel 28 is raised and lowered. The control system may use the reel arm pitch RAP relative to a horizontal canopy reference and a constant sensor angle SAC to determine the angle of the cone axis CA relative to a vertical reference line VRL. Using the above variables and any others as needed, the control system can monitor the perpendicular ground distance GDP as well as the perpendicular crop distance CDP.

[0062] Monitoring of these variables allows calculation of the stubble height SH. The header control system and its reel control system can therefore process the data for the variables as well as the sensor data from the sensors 35 to automatically vary the reel height of the reels 28 during field operations.

[0063] Generally, Figure 12 illustrates a control routine performed by the system CPU in reliance upon the manual inputs and the sensor-based inputs to control the height of the reels 28 and the reel engagement RE. The operating system may comprise a computing device on the combine 10 or remote therefrom, which includes the CPU and other computer-based devices operating a control program and configured to receive inputs, process data, and generate outputs. A detailed discussion of the computing environment is not required for an understanding of the present invention. For purposes of discussion, Figure 12 may be referenced as a routine but also may be characterized as a process of the operating program to process data, receive inputs and generate outputs for use by other routines or processes to automatically raise and lower the reels 28 or for use by the operators of the operating system.

[0064] In more detail as to Figure 12, this figure illustrates a reel height control routine or process of a control system and an operating method of the control system for controlling reel height. As mentioned, the routine is performed by the combine operating or control system which comprises a computing device with a central processing unit (CPU) configured tocommunicate inputs and outputs for data and commands, data storage, and a display device for use by an operator.

[0065] As illustrated, the routine starts at step 40, and in step 41, selected control settings are input into the control system, such as by an operator, wherein the control settings or inputs include a target value for reel engagement RE, which the reel control system will tend to maintain during field operations. Further in step 41, the operator will input a preferred aggressiveness value, which preferably is between 1-10. The operator may make this determination based upon subjective evaluation of field conditions, although the aggressiveness value may be varied by the field operator as field conditions change. In some configurations, the aggressiveness value might be adjusted by the control system itself. The operator may also input a numerical value for deadband, which is the permissible variance between a set value and an actual value before the operating system reacts to adjust the operation of the header 12 and the reel height RH thereof. This deadband is discussed further herein relative to subsequent processing steps.

[0066] Next in step 42, the header position sensors detect the position of various header components, wherein header position sensors may provide data inputs for the reel height position, a fore-aft position for the reel 28, the header pitch HP and a cab pitch for the combine 10 itself, which may be represented by the combine pitch CP or calculated therefrom.

[0067] In step 43, the operating system determines the canopy distance CD and ground distance GD referenced as the canopy range and ground range. In step 44, the sensor data from the sensors 35 may be filtered to compensate for lower density crop conditions or even the absence of growing crop and the presence of stubble.

[0068] In step 45, a canopy range average and ground range average is calculated to compensate for differences in canopy height and ground contours. Further, the actual reel engagement can be calculated from the sensor data.

[0069] In step 46, the process calculates a reel engagement error, which is the difference between the actual reel engagement calculated in step 45 minus the reel engagement target input in step 41.

[0070] In step 47, the reel engagement error is compared relative to the deadband value wherein this comparison step determines whether the reel engagement is lower than the target reel engagement minus half the deadband value. If YES, step 48 lowers the reel 28 and then the routine returns through loop 49 to step 42. If NO, the process passes to step 50 wherein the reel engagement error is compared relative to the deadband value such that this comparison stepdetermines whether the reel engagement is higher than the target reel engagement minus half the deadband value. If YES, step 51 raises the reel 28 and then the routine returns through loop 52 to step 42. If NO, the routine has confirmed that the actual reel engagement is within the range of the deadband value for the target reel engagement. In such instance, the process moves to Step 53 to hold the reel 28 at the set height, and the subroutine ends at Step 54 and then returns through the control loop 55 to the start at Step 40 for continued and continuous monitoring of the actual reel engagement.

[0071] Figure 13 is a flowchart showing the operational process for filtering the sensors to determine if crop height is present and further, whether it is so low as to indicate that stubble is present and being sensed instead of standing crop. As referenced above relative to sensor filtering step 44 in Figure 12, the sensor data from the sensors 35 may be filtered to compensate for lower density crop conditions or even the absence of growing crop and the presence of stubble. When a low crop or stubble condition is identified by a particular sensor 35, the inventive operating system preferably ignores the sensor data when averaging the crop height in step 45 of Figure 12. The sensor data can be ignored or omitted from the crop height averaging calculation performed in step 45 based upon a preset parameter, such as a set period of time. At the end of this set period, the sensor data may be checked again relative to canopy height, and either be included in the crop height averaging algorithm or be ignored until the next successive time period.

[0072] Referring in more detail, Figure 13 illustrates the flowchart for this sensor filtering process for filtering the data streams from the sensor(s) 35. Similar to the above description, this process or routine is performed by the system CPU in reliance upon the data streams input from the sensors 35 that are indicative of the canopy distance CD and the ground distance GD and any other variable sensed thereby. The operating system may comprise a computing device located on the combine 10 or remote therefrom, which includes the CPU and other computer- based devices operating a control program and configured to receive inputs, process data, and generate outputs. Here again, a detailed discussion of the computing environment is not required for an understanding of the present invention. The sensor filtering process is performed as the function of step 44 of the operating process shown in Figure 12 as described further below.

[0073] This sensor filtering process starts at step 60, and next in step 61, the header position sensors detect the position of various header components, wherein header position sensors may provide data inputs for the reel height position, the header pitch HP and a cab pitch for the combine 10 itself, which may be represented by the combine pitch CP or calculated therefrom.

[0074] In step 62, the operating system determines the canopy distance CD and ground distance GD referenced as the canopy range and ground range. In step 63, a sensor pitch correction may be performed as described below relative to Figure 14. In step 64, a cut height average is calculated to based upon sensor data indicating the position of the cutter bar assembly 16 relative to the ground.

[0075] In step 65, the crop height is determined for a particular sensor 35, wherein this routine of step 44 would be performed for each of the sensors 35 separately from the other sensors 35. As such, the crop height CH (See Figure 11) is determined at each one of the sensors 35 for further processing relative to the cut height average of step 64.

[0076] In step 66, the actual crop height at a particular sensor 35 is compared with the cut height average to determine whether the actual crop height is less than the cut height average less the deadband value therefor. If NO, the actual crop height is not less than the cut height average less deadband, then the actual crop height is higher than cut height and the routine moves to step 67 to determine that the sensor data is valid and the routine indicates that the data from this particular sensor 35 may be included in step 45 and the subsequent steps of Figure 12. The routine then ends at 69, which is the end of step 44, and then step 45 is performed. The sensor data may be used in the process steps following step 44 to calculate the canopy range average and the reel engagement actual of step 45 of Figure 12. Therefore, the sensor data for this particular sensor 35 is not used in the process steps following step 44 such as step 45 of Figure 12 to calculate the canopy range average and the reel engagement actual.

[0077] In view of the foregoing, the presence of stubble is not able to skew the reel engagement calculations in steps 46, 47 and 50. Rather each sensor 35 is evaluated to ensure it is not detecting stubble and if any one or more sensor(s) 35 are passing over stubble, the sensor data for each said sensor 35 is ignored by the reel height control process of Figure 12. Each sensor 35 is ignored through each iteration of the process of CH is higher than the cut height, which would indicate that crop canopy is being detected by the sensors 35 rather than stubble.

[0078] Next, Figure 14 is a flowchart showing the operational process for sensor pitch correction of step 63 in the sensor filtering routine of Figure 13. In accord with the above description, the sensor pitch correction routine is performed by the combine operating or control system which comprises a computing device with a central processing unit (CPU) configured to communicate inputs and outputs for data and commands, data storage, and a display device for use by an operator. This CPU or another CPU may be configured to perform the processes of Figures 12- 14.

[0079] The sensor pitch correction routine is performed at step 63 in the routine of Figure 13. In Figure 14, this sensor pitch correction process starts at step 70, and next in step 71, the header position sensors provide the data for the position of various header components, wherein header position sensors may provide data inputs for the reel height position, the header pitch HP and a cab pitch for the combine 10 itself.

[0080] In step 72, the operating system determines the canopy distance CD and ground distance GD referenced as the canopy range and ground range. In step 73, a calculation step is performed to determine the perpendicular ground distance and perpendicular canopy distance based upon the reel arm pitch RAP as these variables are shown in Figure 11.

[0081] In particular, the canopy distance CD is multiplied by the cosign COS of the reel arm pitch RAP minus the sensor angle constant SAC to determine the perpendicular canopy distance CDP. Similarly, the ground distance GD is multiplied by the cosign COS of the reel arm pitch minus the sensor angle constant SAC to determine the perpendicular ground distance GDP. Preferably, the sensors 35 are aimed forwardly of the header 12 and the vertical reference line VRL so that the sensors 35 do not detect header 12 structure when the sensor support 36 is lowered. As such, the crop distance CD and ground distance GD are detected at an angle relative to the vertical reference line VRL. However, this calculation step 73 converts the crop distance CD and ground distance GD detected by the sensors 35 to the perpendicular canopy distance CDP and perpendicular ground distance GDP, which extend vertically. These values for the perpendicular canopy distance CDP and perpendicular ground distance GDP are then used in steps 64 and 65 of Figure 13 to determine the cut height average and the crop height and also are used in step 45 of Figure 12 to determine the canopy range average and the ground range average to compensate for differences in canopy height and ground contours, which may cause the reel arm pitch RAP to vary.

[0082] This routine ends at step 74 and then returns to step 64 wherein step 64 and the subsequent steps of the sensor filtering routine (Figure 13) are performed. This allows the calculation steps 64 and 65 to use the perpendicular ground distance values and perpendicular canopy distance values for the calculations performed for these steps.

[0083] With this control system, the header control system can operate to automatically adjust the reel height relative to the crop canopy as well as the ground. The reel control system can automatically adjust the reel height during changes to the crop height by instantaneously processing the sensor data, which can be averaged over a period of time. Adjustments are made at the end of each of these periods of time. Further, the target reel engagement can bedetermined by biasing the calculation relative to higher or lower canopy ranges by the level of aggressiveness (or bias) of the reel engagement target. This setting allows machine operators to tune the performance of the reel control for downed crop conditions. This is important as crop height and condition can vary across the width of the header. Additionally, the control system utilizes the aggressiveness setting that biases the sensor averaging algorithm towards shorter crop on the one hand or taller crop on the other hand depending upon the aggressiveness value.

[0084] Although particular preferred embodiments of the invention have been disclosed in detail for illustrative purposes, it will be recognized that variations or modifications of the disclosed apparatus, including the rearrangement of parts, lie within the scope of the present invention.

Claims

CLAIMS1. A method for controlling a header control system of a combine header comprising a cutter bar assembly configured to cut field crops and at least one reel configured to engage a crop canopy by an amount of reel engagement therewith, said header control system further comprising one or more sensors for sensing a ground location and sensing a crop canopy as said combine header transits the field, said header control system comprising a reel control system configured to perform the steps of: determining a canopy distance of said crop canopy from said header to determine a reel height of said reel relative to said crop canopy and said ground location; defining a target reel engagement with said crop canopy, wherein said target reel engagement is defined by said reel height of said reel above said ground location and a distance said reel protrudes below a top of said crop canopy with said reel at said reel height; monitoring said crop canopy and said ground location to determine said crop height defined thereby; maintaining said reel height relative to said crop height such that an actual reel engagement is equal to said target reel engagement; and automatically adjusting said reel height to maintain said actual reel engagement proximate to said target reel engagement in response to detected changes in said crop height of said crop canopy to provide automatic control of said reel height based upon said target reel engagement.

2. The method according to Claim 1, wherein said one or more sensors are configured to both sense said crop canopy to determine said crop distance which is defined between said crop canopy and a respective one of said one or more sensors and sense said ground location to determine said ground distance of said ground location from said respective sensor.

3. The method according to Claim 2, wherein said sensors are spaced apart from each other across a width of said header in front of said reel to sense said canopy distance and said ground distance ahead of said reel as said combine moves through the field.

4. The method according to Claim 1, wherein said adjusting step further comprises the steps of raising and lowering said reel relative to said header to provide said automatic adjusting of said reel height.

5. The method according to Claim 1, wherein said method further comprises the steps of: providing a plurality of said sensors; and averaging said cut heights determined from said plurality of sensors.

6. The method according to Claim 5, wherein said method further comprises the steps of obtaining instantaneous values for said cut heights determined from said sensors with said averaging of said cut heights being averaged over successive time periods.

7. The method according to Claim 6, wherein said adjusting of said reel height is made at a respective end of each of said successive time periods.

8. The method according to Claim 5, wherein said method further comprises the step of setting an aggressiveness setting that biases said averaging of said cut heights based upon shorter and taller crops.

9. The method according to Claim 8, wherein said aggressiveness setting has a range between a first aggressiveness setting wherein said target reel engagement tends to be based upon a shorter crop detected by said sensors and a second aggressiveness setting wherein said target reel engagement tends to be based upon a taller crop detected by said sensors.

10. The method according to Claim 1, wherein said method further comprises the step of filtering sensor signals from said one or more sensors for low density crop conditions.

11. A method for controlling a header control system of a combine header comprising a cutter bar assembly configured to cut field crops and at least one reel configured to engage a crop canopy by an amount of reel engagement therewith, said header control system further comprising a plurality of sensors spaced from each other along said header for sensing a groundlocation and for sensing a crop canopy as said combine header transits the field, said header control system comprising a reel control system configured to perform the steps of: defining a target reel engagement with said crop canopy, wherein said target reel engagement is defined by a reel height of said reel above said ground location and a distance said reel protrudes below a top of said crop canopy with said reel at said reel height; setting an aggressiveness setting having a range between a first aggressiveness setting so that said target reel engagement is biased toward a shorter crop detected by said sensors and a second aggressiveness setting so that said target reel engagement is biased toward a taller crop detected by said sensors; determining a canopy distance of said crop canopy from said header to determine a reel height of said reel relative to said crop canopy and said ground location; monitoring said crop canopy and said crop height defined between said crop canopy and said ground location; averaging said crop heights determined from said plurality of sensors; maintaining said reel height such that an actual reel engagement is proximate to said target reel engagement and is based upon said aggressiveness setting; and automatically adjusting said reel height to maintain said actual reel engagement proximate to said target reel engagement in response to detected changes in said crop height of said crop canopy for automatic control of said reel height.

12. The method according to Claim 11, wherein said one or more sensors are configured to both sense said crop canopy to determine said crop distance and sense said ground location to determine said ground distance between said ground location and each of said sensors.

13. The method according to Claim 12, wherein a plurality of said reels are provided and a plurality of said sensors are spaced apart from each other across a width of said header in front of each said reel to sense said canopy distance and said ground distance ahead of each said reel and permit said averaging of said crop heights across the width of said header to determine an average crop height, said reels being adjustable together in unison or independent of each other said reel.

14. The method according to Claim 13, wherein said adjusting step further comprises the steps of raising and lowering said reel relative to said header to provide said automatic adjusting of said reel height based upon said target reel engagement, said average crop height and said aggressiveness setting.

15. The method according to Claim 14, wherein said method further comprises the steps obtaining instantaneous values for said crop heights determined from said sensors with said averaging of said crop heights being averaged over a successive periods of time, and said adjusting of said reel height is made at a respective end of each of these periods of time.

16. A combine header configured to adjust a reel position as said header transits a field, said combine header comprising: a header frame; a cutter bar assembly mounted on said header frame for cutting field crops at a cut height; at least one reel configured to engage a crop canopy by an amount of reel engagement therewith and sweep said crop canopy toward said cutter bar assembly; one or more sensors mounted on said header for sensing a ground location and sensing a crop canopy as said combine header transits the field; a header control system comprising a reel control system configured to: determine a canopy distance of said crop canopy from said header to determine a reel height of said reel relative to said crop canopy and said ground location; monitor said crop canopy and said crop height defined thereby; define a target reel engagement with said crop canopy, wherein said target reel engagement is defined by said reel height of said reel above said ground location and a distance said reel protrudes below a top of said crop canopy with said reel at said reel height; maintain said reel height such that an actual reel engagement of said reel with said crop canopy is proximate to said target reel engagement; and automatically adjust said reel height to maintain said actual reel engagement proximate to said target reel engagement in response to detected changes in said crop height of said crop canopy for automatic control of said reel height based upon said target reel engagement.

17. The combine header according to Claim 16, wherein a plurality of said reels are provided in a reel assembly, wherein said reel assembly is configured to adjust said reel heightfor raising and lowering said reels together in unison or said reels independently of each other relative to said header to provide said automatic adjusting of said reel height of each said reel based upon said target reel engagement.

18. The combine header according to Claim 17, wherein said header control system is configured to average said cut heights from a plurality of said sensors over successive time periods wherein said reel height is adjusted at a respective end of each of said successive time periods.

19. The combine header according to Claim 16, wherein said aggressiveness setting is adjustable as said combine transits the field depending upon a presence or absence of lodged field crops.

20. The combine header according to Claim 16, wherein said target reel engagement and said actual reel engagement are compared based upon a deadband value wherein said target reel engagement and said actual reel engagement are proximate to each other when a difference is less than said deadband value.

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