Combine Harvester Residual Grain Sensor With Switchable Re-Threshing
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Solution Overview
Problem
Existing combine harvesters struggle to detect and minimize threshing losses of grains that are not fully threshed and are discharged back onto the field, leading to inefficiencies and increased energy consumption when attempting to optimize threshing processes.
Innovation Solution
A combine harvester with a separation stage equipped with a switchable post-threshing device and a grain sensor at the second outlet, allowing real-time detection and adjustment of threshing parameters to minimize threshing losses without significantly impacting energy consumption or grain quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If a grain sensor is installed in the discharge chute to detect grains in the residual flow, then grain losses can be minimized, but threshing losses (grains attached to ear fragments) cannot be detected
Solution Approach 1:
The separation stage is divided into an upstream section with the first outlet for useful stream and a downstream section with the second outlet for residual stream. The switchable post-threshing device is specifically positioned in the downstream section to target only the residual flow containing threshing losses, allowing selective processing without affecting the main threshing operation upstream.
Solution Approach 2:
The switchable post-threshing device acts as an intermediary between the separation stage and the field discharge. It provides an additional threshing action specifically for the residual stream, bridging the gap between the main threshing operation and the final grain recovery, enabling detection and recovery of threshing losses that would otherwise be lost.
2Loss of substance
If more intensive threshing is applied to reduce threshing loss, then grain recovery improves, but energy consumption increases and broken grain fraction increases
Solution Approach 1:
The post-threshing device is designed to be switchable rather than continuously operating. It can be activated periodically or selectively based on detected threshing losses, providing intensive threshing action only when needed to recover grains in the residual stream, rather than continuously applying high energy input throughout the harvesting process.
Solution Approach 2:
Instead of applying intensive threshing to the entire crop stream, the post-threshing device applies partial threshing action only to the residual stream portion that contains threshing losses. This targeted approach recovers grains without subjecting the entire harvest to excessive threshing energy input that would increase broken grain fraction.
3Loss of substance
If the post-threshing device is continuously operated to minimize threshing losses, then grain recovery improves, but the share of total operating time increases energy consumption and broken grain content
Solution Approach 1:
The post-threshing device incorporates switchability, allowing its operational status to dynamically change between active and inactive states. This dynamic control enables the system to adapt to varying threshing loss conditions, activating the device only when threshing losses are detected and deactivating it when losses are minimal, thereby optimizing the balance between grain recovery and overall harvesting efficiency.
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 reduces threshing losses by optimizing threshing operations based on real-time grain sensor data, maintaining energy efficiency and grain quality by minimizing the active time of the post-threshing device.
Implementation Method 1
This sensor uses the intensity of the noise generated by the grains in the residual flow upon impact with a surface to determine the quantity of grains in the partial flow
Data Source
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Figure 5~6
AI summary
A combine harvester comprises a separation stage (6) which has an input (20) for a crop flow, a first output (23) for a usable stream derived from the crop flow and rich in threshed grains, and a second output (38) for a residual stream with a low grain content. A discharge chute (40) connected to the second output (38) discharges the residual stream from the combine harvester, and a residual grain sensor (41) is arranged on the discharge chute (40) to detect the proportion of threshed grains in the residual stream. A switchable re-threshing device (31) is provided at the second output (38) of the separation stage (6).