Corn Cutter Contour Tracking for Kernel Yield
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Solution Overview
Problem
Existing automatic corn cutters damage kernels and reduce yield due to their reliance on predetermined cutting patterns that do not conform to the shape of the cob, require precise ear alignment, and are susceptible to debris interference, leading to inefficiencies and kernel loss.
Innovation Solution
The system employs a remotely positioned sensor, such as a linear variable differential transformer (LVDT), to track the contour of each ear of corn, allowing the cutting knives to adjust their depth and follow the actual surface, enabling efficient cutting regardless of ear alignment or debris, and eliminating the need for alignment equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a mechanical sensor finger physically rides on the surface of the ear to detect contour, then the cutting knives can follow the cob shape, but the sensing finger is thrown off course by husk fragments or debris
Solution Approach 1:
The patent replaces the mechanical sensing finger with an optical sensing system. The optical sensor detects the contour of the ear of corn without physical contact, eliminating the problem of the mechanical finger being thrown off course by debris. The optical sensor beam passes through or over the ear to detect the surface profile, providing reliable detection regardless of husk fragments or other contaminants on the ear surface.
2Ease of operation
If prior art alignment apparatus is used to align ears tip-end first, then cutting can be performed, but some damage occurs in handling and 5% of usable kernels are lost when ears are incorrectly presented
Solution Approach 1:
The patent employs a dynamic cutting system where the cutting knives are controlled to adapt to the actual contour of each ear of corn as it passes through. Rather than requiring static alignment of ears in a specific orientation, the system dynamically adjusts the cutting path to follow the detected surface profile of whichever end of the ear is presented first. This eliminates the need for alignment apparatus and prevents kernel damage from forced alignment.
Solution Approach 2:
The system changes the cutting parameters (knife position, depth, and trajectory) based on real-time detection of the ear's contour. By measuring the actual surface profile with the optical sensor and adjusting cutting parameters accordingly, the system can process ears in any orientation while maintaining cutting precision and avoiding kernel damage.
3Productivity
If knives are programmed to ride an imaginary cob with a predetermined pattern, then cutting can be performed efficiently, but the pattern does not conform to the actual shape of the cob resulting in damaged kernels
Solution Approach 1:
The patent performs preliminary detection of the ear's contour using an optical sensor before the cutting process. The sensor measures the actual surface profile of the ear, and this information is used to pre-program or pre-adjust the cutting knife trajectory and depth. This preliminary measurement allows the cutting knives to follow the actual cob shape rather than an imaginary predetermined pattern, ensuring both efficiency and precision.
Solution Approach 2:
The system implements a feedback loop where the optical sensor continuously detects the ear's surface profile during processing, and this information feeds back to control the cutting knife position and depth. The cutting operation is adjusted in real-time based on the detected contour, ensuring the knives follow the actual shape of the cob and minimize kernel damage while maintaining high cutting 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
This approach significantly increases the yield of usable whole kernels by reducing damage and allowing for efficient cutting of ears presented either 'tip end' or 'butt end' first, thereby minimizing kernel loss and operational complexity.
Implementation Method 1
The sensor is preferably a linear variable differential transformer of LVDT. The LVDT is mounted remotely from the ear, and senses the movement of at least one of the drive shafts carrying the drive or feed rollers relative to the axis of rotation of the ears of corn.
Data Source
AI summary
An automatic corn cutting apparatus for cutting kernels off of husked ears of corn. The ears may be presented to the cutting knives either tip end or butt end first. The ears are fed into the cutting knives by a pair of drive rollers carried by a pair of articulating drive shafts. The drive shafts move in a plane perpendicular to the axis along which the ears are fed to the cutting knives. A sensor, preferably a linear variable differential transformer, or LVDT, is carried by one of the drive shafts remotely from the ears, i.e. the LVDT does not contact the ears. The sensor detects the profile of each ear of corn, and the profile is used by a knife controller to efficiently remove the kernels from each ear of corn.