Corn Ear Width Sensing 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 sizes in the field.
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
1Reliability
If the spacing between deck plates is adjusted to block larger corn ears, then ear loss is prevented, but stalks may be unable to pass through the gap
Solution Approach 1:
The deck plate spacing is made dynamically adjustable rather than fixed. The system continuously monitors corn ear width and automatically adjusts the gap size to match the actual crop conditions, allowing the spacing to adapt in real-time between larger and smaller ears throughout the field.
Solution Approach 2:
The system incorporates sensors that continuously measure corn ear width and provide feedback to the control system. This feedback loop enables the deck plate spacing to be automatically adjusted based on actual ear size measurements, ensuring optimal separation without manual intervention.
2Productivity
If the spacing between deck plates is reduced to block corn ears, then harvesting efficiency improves, but stalks cannot pass through the gap
Solution Approach 1:
The deck plate spacing transitions from a static setting to a dynamic, continuously adjustable parameter. The system responds to real-time variations in corn ear width by automatically modifying the gap size, maintaining high harvesting efficiency across diverse crop conditions without manual reconfiguration.
Solution Approach 2:
The physical parameter of deck plate spacing is changed dynamically based on measured corn ear width. The system adjusts this critical parameter in response to varying crop conditions, enabling optimal performance across different ear sizes throughout the field.
3Loss of time
If manual adjustment of deck plate spacing is performed, then setup time is reduced, but the system cannot adapt to varying ear sizes throughout the field
Solution Approach 1:
Continuous sensor feedback on corn ear width enables automatic adjustment of deck plate spacing throughout the harvesting operation. This eliminates the need for manual adjustments while providing ongoing adaptation to varying ear sizes encountered at different locations in the field.
Solution Approach 2:
The system performs self-adjustment of deck plate spacing based on its own sensor measurements of corn ear width. The harvester automatically configures the optimal gap size without operator intervention, adapting continuously as it moves through areas with different ear size characteristics.
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 determines corn ear width and adjusts deck plate spacing to prevent ear loss while enabling stalk passage, thereby enhancing harvesting efficiency.
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
AI summary
A corn ear monitoring system for an agricultural harvester includes a controller having a memory and a processor. The controller is configured to 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. The controller is also configured to 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.