Combine Residue Spread Monitoring With Imaging-Based Control

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Solution Overview

Problem

Existing agricultural combines face challenges in efficiently and evenly distributing residue material during harvesting, which can lead to uneven soil coverage, erosion, and inconsistent plant emergence due to manual adjustments being complex and time-consuming, and existing automated systems are not comprehensive.

Innovation Solution

A system utilizing an imaging sensor mounted on the unloading auger of a combine harvester to monitor residue distribution, coupled with an inertial measurement unit (IMU) for orientation correction, and controllers to analyze image data and adjust operational parameters such as steering vanes or rotors to achieve uniform residue spread.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If manual monitoring and adjustment of spreader tool is used, then operational simplicity is maintained, but residue distribution uniformity deteriorates due to operator fatigue and time-consuming adjustments

Engineering Contradiction:

Improveresidue distribution uniformityVSAvoidoperational complexity

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The system enables self-service automation where the spreader tool automatically adjusts its operation based on real-time sensor feedback and image analysis, eliminating the need for continuous manual monitoring and adjustment while maintaining consistent residue distribution uniformity

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual mechanical adjustment operations with an automated system comprising sensors, image processing, and electronic control mechanisms that automatically regulate spreader tool performance based on measured residue distribution patterns

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If automated control systems with sensors are implemented, then residue distribution precision is improved, but device complexity increases due to multiple sensors and control mechanisms

Engineering Contradiction:

Improveresidue distribution precisionVSAvoidsystem complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The system employs multi-functional components where sensors serve multiple purposes (monitoring residue distribution, detecting operating conditions, tracking machine position) and the control system integrates various functions into a unified automated management platform, reducing overall system complexity despite enhanced precision capabilities

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent combines multiple sensing functions, image processing capabilities, and control mechanisms into an integrated automated system that operates as a cohesive unit, thereby managing complexity through consolidation rather than separate independent systems

Inventive Principle:

Principle #5Merging (Combining)

3Manufacturing precision

If real-time monitoring is implemented, then residue distribution control is improved, but time consumption increases due to data processing and adjustment operations

Engineering Contradiction:

Improvedistribution control accuracyVSAvoidadjustment time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The system implements real-time feedback loops where sensors continuously monitor residue distribution, image processing immediately analyzes the data, and the spreader tool automatically adjusts its operation without human intervention, eliminating time losses associated with manual observation and adjustment cycles

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The automated system maintains continuous monitoring and adjustment operations without interruption or downtime, ensuring uninterrupted harvesting productivity while achieving precise residue distribution control through ongoing real-time regulation

Inventive Principle:

Principle #20Continuity of useful action

4Manufacturing precision

If spreader tool adjusts for wind direction, then residue spread uniformity is improved, but device complexity increases due to additional control mechanisms

Engineering Contradiction:

Improveresidue spread uniformityVSAvoidcontrol mechanism complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The spreader tool incorporates self-service wind compensation where sensors detect wind conditions and the control system automatically adjusts spreader operation in response, eliminating the need for separate manual wind correction mechanisms while maintaining uniform residue distribution

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS12406505B2Residue spread monitoring

Publication Date: 2025.09.02 AGCO INT GMBH

AI summary

Systems and methods for monitoring the distribution of residue material from a spreader tool of an agricultural machine including an imaging sensor coupled to an unloading auger of the agricultural machine used to image an area to the rear of the agricultural machine where the Image data is analysed to determine a distribution of residue material associated with the spreader tool and one or more operational parameters of the agricultural machine or components are controlled based on the determined distribution.