Air Pressure Sensor Detects Plugging in Combine Discharge Path
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Modern agricultural combines face challenges with plugging in crop residue discharge systems, leading to downtime and reduced productivity due to inadequate detection of plugging conditions, which can result in blockages and interference with chaff handling systems.
Innovation Solution
A system and method utilizing an air pressure sensor located between the cleaning and separating systems to detect changes in air pressure indicative of reduced crop residue flow, allowing for early warning and automatic adjustment to prevent plugging, featuring a crop residue chopper and conveyor mechanism with control systems to determine plugging conditions based on sensed air pressure and operational parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional discharge systems (straw walkers or discharge beaters) are used to transport crop residue, then the system structure is relatively simple, but the material handling capability is limited and plugging occurs frequently
Solution Approach 1:
The patent employs a rotary beater that rotates at high speed to dynamically propel crop residue rearwardly, replacing the static or slow-moving traditional discharge systems. This dynamic mechanism significantly increases material handling capability while maintaining reliable discharge by preventing residue accumulation through continuous motion and impact forces.
2Reliability
If no detection system is installed, then the device complexity is low, but plugging conditions are not detected until severe blockage occurs, causing substantial downtime
Solution Approach 1:
The patent incorporates air flow sensors that continuously monitor air flow conditions in the discharge path and provide feedback to the control system. When the sensor detects air flow restrictions indicating developing plugging conditions, the control system responds by adjusting operational parameters or alerting the operator, enabling early intervention before severe blockage occurs.
Solution Approach 2:
The patent replaces complex mechanical detection systems with electronic air flow sensors that measure air pressure or flow characteristics. This substitution provides reliable early plugging detection through non-contact sensing, reducing mechanical complexity while improving detection reliability and response time.
3Productivity
If crop residue is discharged at high volume to meet harvesting capacity, then productivity is improved, but the discharge system capacity is exceeded leading to plugging
Solution Approach 1:
The rotary beater provides high-speed dynamic propulsion that can handle increased crop residue volumes without plugging by maintaining continuous motion and using centrifugal forces to prevent accumulation. The system adapts to varying residue volumes through its dynamic operation, allowing high harvesting capacity to be maintained without exceeding discharge capabilities.
Solution Approach 2:
Air flow sensors monitor discharge conditions in real-time and provide feedback when residue volume approaches discharge system capacity. The control system uses this feedback to adjust operational parameters such as beater speed or harvest rate, preventing plugging while maximizing productive output within system capabilities.
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 effectively detects the onset of plugging conditions, reducing downtime and increasing harvesting productivity by providing timely warnings and adjustments to prevent blockages and maintain efficient crop residue discharge.
Implementation Method 1
an air pressure sensor disposed in said space so as to be operable for sensing an air pressure condition in said space indicative of a reduced crop residue flow condition toward a rear end of said space
Data Source
Figure 1
Figure 2~4
Figure 3
AI summary
A system and method for detecting a condition indicative of onset of plugging or actual plugging of a discharge of an agricultural combine (20), utilizing a pressure sensor (100) disposed at a location within the combine spaced from the discharge (112) and operable for sensing an air pressure condition relating to a flow indicative of a reduced crop residue flow condition toward or in the discharge.