Agricultural Harvester Load Detection Using Movable Plate Sensors
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Solution Overview
Problem
Agricultural machinery designed for harvesting tall and stalky plants faces challenges in monitoring operating loads, particularly at critical points like the elevator assembly, leading to potential machine overload, reduced efficiency, increased maintenance costs, and safety risks for operators due to manual and laborious load monitoring.
Innovation Solution
An automatic load detection system comprising a detector mechanism with a movable plate and sensors installed along the processing path, including the elevator assembly, to identify and signal critical load levels, allowing for operational adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual load monitoring is used by operators, then the machine can operate without additional detection systems, but the operator's attention is diverted from other critical tasks and the monitoring process becomes complex and laborious
Solution Approach 1:
The load detection system automatically monitors the processing path without requiring operator intervention. The detector mechanism self-activates when material accumulates, triggering the detection process and signal generation autonomously, freeing the operator from manual monitoring tasks
Solution Approach 2:
The patent replaces manual visual inspection and physical assessment with an automated detector mechanism that uses sensors or mechanical detectors to sense material accumulation and generate electrical signals, substituting human sensory and cognitive processes with automated detection systems
2Reliability
If no automatic load detection system is installed, then the machine structure remains simple, but the machine may reach critical load levels leading to overload, reduced efficiency, and safety risks
Solution Approach 1:
The detector mechanism is positioned to detect material accumulation before it reaches critical overload levels. The system performs preliminary detection and triggers warning signals in advance, allowing operators to take corrective action before dangerous conditions develop
Solution Approach 2:
The patent introduces a detector mechanism as an intermediary element between the material flow and the operator. This intermediary automatically senses load conditions and communicates status through signals, bridging the gap between physical material accumulation and operator awareness without requiring direct operator intervention
3Productivity
If the elevator assembly receives large loads of harvested material, then productivity increases, but the load may exceed limits causing machine damage and increased maintenance costs
Solution Approach 1:
The detection system provides continuous feedback about material accumulation in the processing path. When the detector senses critical load levels, it generates warning signals that feed back to operators, enabling them to adjust operations to maintain productivity while preventing overload damage
Solution Approach 2:
The system performs preliminary detection of load accumulation before it reaches dangerous levels. By detecting and signaling early in the accumulation process, the system allows operators to take preventive action before the load exceeds the machine's safe operating limits
Data Source
AI summary
An automatic load detection system is applied to immediately identify and signal operators when a machine's work operations reach critical load levels, reducing operating risks and improving the machines' working conditions. In one aspect, the system includes a processing path formed by a conveyor roller assembly, a chopper assembly, and an elevator assembly of the machine. The system also includes at least one detector mechanism configured to identify the amount of harvested material in the processing path, wherein the at least one detector mechanism is configured to be installed in at least one location along said processing path and comprises an opening in which a movable plate is disposed, configured to move between a neutral position and an activated position, wherein said movable plate has a face facing the flow of harvested material, and an opposite face comprising a detector.