Auger Gap Control via Corn Ear Imaging

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Solution Overview

Problem

Current agricultural harvesters require skilled operators to manually adjust the auger gap between the auger and trough of corn headers to optimize corn harvesting, which is prone to errors and inefficiencies due to changing crop conditions, potentially damaging corn ears or limiting throughput.

Innovation Solution

An auger gap detection and control system using a controller with a processor and memory, coupled with an internal imaging system, measures the diameter of corn ears and automatically adjusts the auger gap to ensure optimal settings, providing user-indications or adjustments based on detected crop conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If manual adjustment of auger gap by skilled operator is used, then initial setup can be done, but the system cannot adapt to changing crop conditions and is prone to operator error

Engineering Contradiction:

Improveadaptability to changing crop conditionsVSAvoidmanual adjustment requirement

Core Design Contradiction:

Adaptability or versatilityVSExtent of automation

Solution Approach 1:

The system uses imaging sensors to automatically detect corn ear diameter and shellout characteristics, then the controller autonomously adjusts the auger gap position without requiring manual operator intervention. The system serves itself by using its own sensors and actuators to maintain optimal settings based on real-time crop conditions.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system continuously monitors crop conditions through imaging sensors and uses this feedback to dynamically adjust the auger gap. The controller receives image data, analyzes crop characteristics, and automatically modifies the auger position to maintain optimal settings as crop conditions change throughout the field.

Inventive Principle:

Principle #23Feedback

2Object-affected harmful factors

If auger gap is set small to avoid corn damage, then corn ear protection is improved, but throughput capacity is limited

Engineering Contradiction:

Improvecorn ear damageVSAvoidthroughput capacity

Core Design Contradiction:

Object-affected harmful factorsVSProductivity

Solution Approach 1:

The auger gap position is made dynamically adjustable rather than fixed. The system continuously monitors corn ear diameter and shellout characteristics, then automatically adjusts the auger gap position in real-time to optimize both corn protection and throughput based on current crop conditions.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes the physical parameter of auger gap position based on detected crop characteristics. By measuring corn ear diameter and shellout presence, the controller adjusts the auger gap dimension to prevent damage while maintaining adequate throughput capacity for the specific crop conditions.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If auger gap is set large to increase throughput, then productivity is improved, but corn ears may be damaged via wedging contact

Engineering Contradiction:

Improvethroughput capacityVSAvoidcorn ear damage

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

Inventive Principle:

Principle #15Dynamics

4Adaptability or versatility

If mechanical adjustment mechanism is added for automatic control, then adaptability is improved, but device complexity increases

Engineering Contradiction:

Improveautomatic auger gap controlVSAvoidcontrol system complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The system replaces manual mechanical adjustment with an automated control system using imaging sensors and a controller. The mechanical complexity is reduced by using non-contact optical sensing instead of physical measurement devices, and the controller integrates the adjustment logic software-based rather than requiring complex mechanical linkages.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentEP4483699A1System and method for detecting and controlling auger gap via imaging processing

Publication Date: 2025.01.01 CNH INDUSTRIAL AMERICA LLC

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AI summary

The present invention relates to an agricultural harvester (100) with an auger gap detection and control system (118) which includes a controller (120), including a memory (124) and a processor (122). The controller (120) is configured to receive from a sensor, such as a camera (128) a signal indicative of an image of crop material within a feederhouse (107) of the harvester (100). The controller (120) is also configured to analyze the image to measure a diameter of at least one ear of corn of the harvested crop material within the feederhouse (107). The controller (120) is further configured to determine an initial size of an auger gap (222) between an auger (208) and a trough (212) of a header (200) based on the diameter of the at least one ear of corn, the trough (212) being located beneath the auger (208). Preferably, the gap is adjusted by means of an actuator (132) based on the initial size.