Adaptive Threshing Control for Variable Crop Moisture
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Solution Overview
Problem
Agricultural machines face challenges in efficiently processing harvested crops due to varying crop conditions such as moisture and toughness levels, which affect the power requirements of their subsystems like threshing and chopper rotors, leading to inconsistent performance and efficiency.
Innovation Solution
The implementation of a method and system that uses sensors to measure performance parameters like torque and force on knives, along with machine parameters like feed rate and rotational speed, to determine crop conditions and adjust power requirements dynamically through a controller, ensuring optimal processing and energy usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the agricultural machine processes harvested crop with fixed machine parameters, then the device complexity is reduced, but the processing efficiency and energy consumption vary inconsistently due to varying crop conditions
Solution Approach 1:
The patent applies dynamics by making the machine parameters (rotational speed of threshing rotor, rotational speed of chopper rotor, position of opposing knives) variable and adjustable based on real-time crop condition detection. The controller dynamically modifies these parameters to match the actual crop moisture and toughness levels, transforming the system from a fixed-parameter machine to an adaptive one that optimizes processing efficiency for varying crop conditions.
Solution Approach 2:
The patent implements feedback by using sensors to continuously monitor performance parameters (torque of threshing rotor, torque of chopper rotor, force on opposing knives) and comparing them against threshold values. Based on this feedback, the controller automatically adjusts machine parameters to maintain optimal processing conditions, creating a closed-loop control system that responds to actual crop conditions rather than operating on fixed settings.
2Use of energy by moving object
If the agricultural machine uses fixed power settings for threshing and chopper rotors, then the operation is simpler, but energy consumption cannot be optimized for varying crop moisture and toughness levels
Solution Approach 1:
The patent applies self-service by enabling the agricultural machine to automatically detect crop conditions through sensors and adjust its own power settings without requiring manual intervention. The controller monitors performance parameters and autonomously modifies rotational speeds and knife positions to optimize energy consumption for the actual crop conditions, making the system self-regulating rather than requiring operator adjustment.
Solution Approach 2:
The patent implements parameter changes by systematically varying machine parameters (rotational speed of threshing rotor, rotational speed of chopper rotor, position of opposing knives) in response to detected crop conditions. The controller modifies these parameters to match the actual moisture and toughness levels of the harvested crop, optimizing energy consumption for each specific processing condition rather than using uniform power settings.
3Manufacturing precision
If the agricultural machine processes crop without real-time parameter adjustment, then the system is simpler, but crop quality consistency deteriorates due to unoptimized processing conditions
Solution Approach 1:
The patent implements feedback by using sensors to continuously monitor performance parameters (torque of threshing rotor, torque of chopper rotor, force on opposing knives) and comparing them against threshold values. Based on this feedback, the controller automatically adjusts machine parameters to maintain optimal processing conditions, creating a closed-loop control system that responds to actual crop conditions rather than operating on fixed settings.
Solution Approach 2:
The patent applies mechanics substitution by replacing manual mechanical adjustment with an automated electronic control system. Instead of requiring physical adjustment of machine parameters by the operator, the system uses electronic sensors and controllers to automatically detect crop conditions and modify mechanical settings, thereby maintaining consistent crop quality without increasing operational complexity.
Data Source
AI summary
An agricultural machine includes a cutting head configured to harvest crop, a threshing assembly and a crop debris routing assembly configured to process the harvested crop, and a controller. The threshing assembly includes a thresher basket, guide vanes, and a threshing rotor, and the crop debris routing assembly includes opposing knives and a chopper rotor. The controller is configured to receive one or more machine parameters and one or more performance parameters and determine at least one of a moisture level of the harvested crop and a toughness level of the harvested crop based on the received one or more machine parameters and one or more performance parameters. The machine parameters are adjustable inputs to the agricultural machine and the performance parameters are sensed outputs of the agricultural machine.