Adaptive Header Floatation for Tilt and Lift Position
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Solution Overview
Problem
Existing header floatation systems in agricultural vehicles face challenges in maintaining consistent ground reaction force across varying terrain and tilt positions, leading to inefficient operation and excessive wear on components.
Innovation Solution
A control system that determines the relation between header tilt and lift positions and ground reaction force, allowing for adjustment of lift pressure to maintain a desired ground reaction force, thereby optimizing floatation and reducing operator intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If hydraulic pressure is used to control header floatation, then the header can be supported off the ground, but friction and stiction cause pressure readings to be inaccurate measures of actual header height
Solution Approach 1:
The patent introduces an intermediary relationship between hydraulic pressure and header position by using a pressure sensor to measure pressure and a controller to interpret this data in conjunction with accumulator volume information. This intermediary processing layer compensates for the inaccuracies caused by friction and stiction, allowing the system to determine actual header height more accurately than direct pressure measurement alone would provide.
Solution Approach 2:
The system implements feedback by continuously monitoring hydraulic pressure through sensors and using this information, combined with accumulator volume data, to determine actual header position. The controller uses this feedback to adjust the pressure reducing valve and maintain accurate header height control despite the presence of friction and stiction in the hydraulic system.
2Productivity
If manual adjustment of floatation pressure is required to maintain consistent ground force, then operator control is maintained, but operator intervention increases and efficiency decreases
Solution Approach 1:
The system performs self-service by automatically maintaining consistent ground reaction force through the controller's ability to interpret pressure sensor data and accumulator volume information. The controller autonomously adjusts the pressure reducing valve to compensate for changes in header position and terrain variations, eliminating the need for continuous operator intervention and thereby improving operational efficiency.
Solution Approach 2:
The patent replaces manual mechanical adjustment with an automated control system that uses electronic sensors, a controller, and automated valve control. This substitution of manual operation with an automated electromechanical system reduces operator burden and increases productivity while maintaining consistent floatation force.
3Adaptability or versatility
If header tilt is adjusted to adapt to terrain, then ground following capability improves, but ground reaction force becomes inconsistent
Solution Approach 1:
The system uses feedback from pressure sensors and accumulator volume measurements to detect changes in header tilt and position. The controller processes this information and automatically adjusts the floatation pressure to maintain consistent ground reaction force even as the header tilts to follow terrain variations, thus preserving both adaptability and force consistency.
Solution Approach 2:
The system dynamically changes the hydraulic pressure parameter in response to header tilt adjustments. When the header tilts to adapt to terrain, the controller modifies the floatation pressure to compensate for the resulting changes in ground reaction force, thereby maintaining consistent force despite changes in header orientation and position.
4Reliability
If excessive ground force is applied to maintain floatation, then header stability is improved, but wear on skid shoes and cutter bar knives increases
Solution Approach 1:
The feedback mechanism monitors actual header position and hydraulic pressure, allowing the controller to apply only the necessary floatation force required to maintain header stability. By continuously adjusting pressure based on sensor input, the system avoids applying excessive force that would otherwise be needed to ensure stability, thereby reducing wear on skid shoes and cutter bar knives.
Solution Approach 2:
The system applies partial action by providing just enough floatation force to maintain header stability rather than using excessive force. The controller calculates and applies the minimum necessary pressure to keep the header properly positioned and stable, avoiding the harmful effects of over-pressurization and excessive wear on contact components.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system ensures consistent ground reaction force, reducing operator adjustments and minimizing wear on components by automatically adapting to changes in tilt and lift positions, enhancing the overall efficiency and durability of the header floatation system.
Implementation Method 1
A typical accumulator is a reservoir that is fluidly connected to the hydraulic circuit, and contains a volume of pressurized gas. In use, as the header moves over undulating terrain, the gas can expand and contract to provide a spring-like resilience to the hydraulic circuit.
Implementation Method 2
The hydraulic actuators comprise piston and cylinder assemblies that use hydraulic fluid to move the piston relative to the cylinder. The position of the header is controlled by changing the volume of fluid in the cylinder.
Implementation Method 3
The bulk of the weight of the header is supported by lift arms attached to and actuated by hydraulic cylinders.
Data Source
AI summary
Float performance of a header is enhanced by using tilt position and/or lift position changes of the header to automatically adjust ground reaction force when operating conditions require a change in tilt and/or lift position of the header, such as for cutting certain crops, cutting in certain conditions, or to maintain a mechanical advantage. Using an equation to relate the changing down force with the tilt and/or lift positions, the floatation setting of the header is changed to maintain a constant ground reaction force. The adaptive floatation avoids the need for the operator to exit the vehicle to check and, if necessary, adjust the floatation force after each tilt and/or lift adjustment.