Combine Harvester Grain Flow Control via Gate Adjustment
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Solution Overview
Problem
Combine harvester unloading systems face challenges in controlling grain flow rates, leading to potential spillage and difficulty in topping off vehicles, while variable speed drive systems are expensive and require high startup torque.
Innovation Solution
A grain flow rate control system using a gate adjustment structure over cross augers to variably control grain flow, incorporating a control system that adjusts gate positions to manage flow rates and reduce startup torque, enabling soft start and stop functionality without significant equipment investment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If increased flow rates are used to unload grain faster, then unloading speed is improved, but startup torque becomes excessively high
Solution Approach 1:
The system employs variable speed drive mechanism that dynamically adjusts the rotational speed of the unloading auger based on operational requirements. The controller modulates the auger speed to provide high flow rates during normal operation while reducing speed during startup and stopping phases, thereby maintaining high productivity while preventing excessive startup torque demands on the drive system.
Solution Approach 2:
The invention changes the operational parameters of the unloading system by varying the auger rotational speed rather than maintaining a constant high speed. The controller adjusts speed parameters in real-time based on grain flow conditions, vehicle position, and operational phase, enabling the system to achieve fast unloading when needed while reducing torque requirements during transitions.
2Force
If variable speed drive system is used to manage startup torque, then torque control is improved, but system cost increases significantly
Solution Approach 1:
The system utilizes the existing auger motor and controller to provide variable speed operation, eliminating the need for separate variable speed drive equipment. The controller already present in the combine harvester is programmed to manage auger speed variations based on operational conditions, allowing the system to self-regulate torque and speed without additional expensive drive components.
Solution Approach 2:
The auger motor and controller serve multiple functions: they drive the unloading auger, regulate grain flow rate, manage startup and stopping sequences, and control variable speed operation. By making the existing motor and controller multi-functional, the system achieves torque control capabilities without requiring dedicated variable speed drive hardware, thereby reducing overall system cost.
3Productivity
If high flow rates are maintained continuously, then unloading efficiency is improved, but grain spillage increases and topping off becomes difficult
Solution Approach 1:
The system dynamically adjusts grain flow rate by varying auger speed based on real-time conditions. The controller monitors operational phase, vehicle position, and grain flow characteristics to modulate the auger speed, enabling high flow rates during efficient unloading phases while reducing flow rates during topping off and stopping phases. This dynamic adjustment prevents grain spillage while maintaining high overall unloading efficiency.
Solution Approach 2:
The controller incorporates feedback mechanisms that monitor grain flow conditions, vehicle fill level, and operational status to automatically adjust auger speed. Sensors detect changes in grain flow rate and vehicle position, and the controller responds by modulating the auger speed accordingly, ensuring optimal flow control that prevents spillage while maintaining efficiency. The feedback system enables precise flow rate management throughout the unloading cycle.
Data Source
AI summary
In a grain unloading system for a combine harvester a grain bin includes a frame, the frame has a floor with a trough. An unloading auger is disposed at least partially within the trough. An auger cover at least partially covers the auger. The auger cover has a hat for a top portion of the auger cover and a pair of gates movable between the hat and locations on the floor that are proximal to the trough. A gate adjustment structure is coupled to the pair of gates to move the pair of gates relative to the auger. A control system is coupled to the gate adjustment structure and configured to control the gate adjustment structure.