Corn Ear Width Monitoring for Adaptive Deck Plate Spacing
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Solution Overview
Problem
Operators face difficulty in adjusting the spacing between deck plates of a corn header to effectively block corn ears while allowing stalks to pass through, due to varying crop conditions such as ear size in agricultural harvesting.
Innovation Solution
A corn ear monitoring system with a controller, camera, and actuators that determine the width of corn ears using image processing and adjust deck plate spacing accordingly to enhance harvesting efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the spacing between deck plates is manually adjusted to block larger corn ears, then larger ears are blocked effectively, but smaller ears may be incorrectly blocked and stalks may fail to pass through
Solution Approach 1:
The patent replaces the manual mechanical adjustment system with an automated optical measurement and control system. A camera captures images of corn ears, the controller processes these images to determine ear width, and actuators automatically adjust the deck plate spacing based on the measured width, eliminating the need for manual adjustment and improving accuracy.
Solution Approach 2:
The system enables the corn header to automatically measure and adjust to each corn ear's dimensions as it passes by. The camera continuously captures images, the controller calculates the required spacing in real-time, and the actuators make immediate adjustments, allowing the system to adapt to varying ear sizes without operator intervention.
2Adaptability or versatility
If a fixed deck plate spacing is used, then the structure is simple and reliable, but it cannot adapt to varying corn ear sizes throughout the field
Solution Approach 1:
The patent transforms the static, fixed deck plate spacing into a dynamic, adjustable system. The deck plate spacing changes in real-time based on the measured width of each corn ear, allowing the system to adapt to varying crop conditions while maintaining effective separation of ears and stalks.
Solution Approach 2:
The system implements a closed-loop feedback mechanism where the camera continuously monitors corn ear width, the controller processes this information to determine the optimal spacing, and the actuators adjust the deck plates accordingly. This feedback loop ensures the system continuously adapts to varying ear sizes throughout the field.
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
Accurately controls deck plate spacing to block corn ears while allowing stalks to pass, enhancing the efficiency of the harvesting operation.
Implementation Method 1
receive an image of an ear of corn in contact with a first side of a transparent panel from a camera positioned on a second side of the transparent panel
Implementation Method 2
determine a determined width of the ear of corn based on a distance between the camera and the first side of the transparent panel and a monitored width of the ear of corn within the image
Data Source
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AI summary
A corn ear monitoring system (300) for an agricultural harvester (100) includes a controller (304) having a memory (308) and a processor (306). The controller (304) is configured to receive an image of an ear of corn (400) in contact with a first side (318) of a transparent panel (316) from a camera (302) positioned on a second side (320) of the transparent panel (316). The controller (304) is also configured to determine a determined width (DD) of the ear of corn (400) based on a distance (L) between the camera (302) and the first side (318) of the transparent panel (316) and a monitored width (DM) of the ear of corn (400) within the image.