Corn Header Kernel Sensor Dynamic Deck Plate Control

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Solution Overview

Problem

Current corn header technologies face issues with deck plate spacing, leading to kernel loss due to either excessive gap allowing ears to get stuck or pinching force causing stalk damage, and existing solutions like manual adjustment or spring-mounted deck plates are not effective in all scenarios.

Innovation Solution

A corn header with a kernel sensor system that detects detached kernels and generates a signal to adjust the width of the stalk receiving channel using an actuator assembly, ensuring optimal deck plate positioning to minimize kernel loss and stalk damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If the deck plates are spaced far apart to reduce pinching force on stalks, then stalk damage is reduced, but corn ears get stuck between the deck plates causing kernel loss

Engineering Contradiction:

Improvestalk damageVSAvoidkernel loss

Core Design Contradiction:

Object-affected harmful factorsVSLoss of substance

Solution Approach 1:

The deck plates are made movable rather than fixed, allowing them to dynamically adjust their spacing in response to varying stalk diameters. This dynamic adjustment enables the system to maintain optimal contact pressure for different stalk sizes, preventing both excessive pinching and ear sticking.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

A sensor system detects the presence and size of stalks in real-time, providing feedback to the control unit which then adjusts the deck plate spacing accordingly. This closed-loop feedback mechanism ensures that the deck plates adapt to current conditions, minimizing both stalk damage and kernel loss.

Inventive Principle:

Principle #23Feedback

2Loss of substance

If the deck plates are spaced closely to prevent ears from getting stuck, then kernel loss is reduced, but stalks get caught and damaged between the deck plates

Engineering Contradiction:

Improvekernel lossVSAvoidstalk damage

Core Design Contradiction:

Loss of substanceVSObject-affected harmful factors

Solution Approach 1:

The deck plates transition from a fixed close-spacing configuration to a dynamically adjustable system that can widen or narrow the gap based on real-time stalk measurements, preventing stalk catching while maintaining ear contact.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The sensor system provides continuous feedback on stalk dimensions, enabling the control unit to adjust deck plate spacing to the precise level needed to prevent both ear sticking and stalk damage.

Inventive Principle:

Principle #23Feedback

3Adaptability or versatility

If manual adjustment of deck plate width is used to optimize harvesting, then adaptability to different conditions is improved, but operator experience and attention are required to avoid suboptimal settings

Engineering Contradiction:

ImproveadjustabilityVSAvoidoperator dependency

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The system performs self-adjustment of deck plate spacing based on sensor feedback, eliminating the need for continuous operator intervention. The harvesting unit automatically adapts to varying stalk conditions, making the system self-regulating and reducing operator dependency.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The automated feedback control system replaces manual operator judgment with sensor-based detection and automatic adjustment, ensuring consistent optimal settings without requiring operator experience or attention.

Inventive Principle:

Principle #23Feedback

4Adaptability or versatility

If spring-mounted deck plates are used to provide automatic adjustment, then adaptability is improved, but sugar and dust accumulation reduces spring force effectiveness over time

Engineering Contradiction:

Improveautomatic adjustmentVSAvoidspring force consistency

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The passive spring-based mechanical adjustment system is replaced with an active controlled system using sensors and actuators. This substitution eliminates the reliability issues of spring degradation while maintaining automatic adaptability through electronic control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The sensor feedback system provides continuous monitoring of actual deck plate spacing and stalk conditions, enabling active compensation for any drift or inconsistency, ensuring reliable and consistent adjustment performance over time.

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS9867334B2Corn header including a kernel sensor and a control unit for controlling desk plates of the corn header

Publication Date: 2018.01.16 BLUE LEAF I P INC

AI summary

A corn header includes a plurality of harvesting units to separate corn ears from corn stalks. Each harvesting unit has a deck plate assembly, and an actuator assembly to adjust a width of a stalk receiving channel by adjusting a position of at least a deck plate of the deck plate assembly. A kernel sensor can generate a signal representative of the presence of kernels detached from the ears during the separation of the corn ears from the corn stalks by the harvesting units and a control unit to receive the signal from the kernel sensor and generate an actuator control signal for controlling the actuator assemblies of the plurality of harvesting units, thereby controlling the width of the stalk receiving channels of the harvesting units.