Corn Header Row Unit Control for Stalk Height Variation
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Solution Overview
Problem
Corn harvesting systems face inefficiencies due to variations in stalk height, leading to stalks entering the harvester along with non-grain material when the header pitch angle is not correctly set, resulting in reduced harvesting accuracy and productivity.
Innovation Solution
A control system for a corn header row unit that utilizes sensors to measure stalk height and adjust the pitch angle and feed roller speed in real-time, ensuring that the entire stalk is pulled beneath the feed rollers before reaching the picking location, thereby preventing non-grain material from being harvested.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the header pitch angle is set for a specific stalk height, then harvesting accuracy is improved for that height, but harvesting accuracy deteriorates when stalk height varies
Solution Approach 1:
The patent implements dynamic adjustment of the header pitch angle based on real-time stalk height measurements. Sensors continuously monitor stalk height and the control system automatically adjusts the pitch angle to maintain optimal harvesting conditions across varying stalk heights, transforming a static system into a dynamic adaptive one
Solution Approach 2:
The system changes the pitch angle parameter in response to measured stalk height variations. By continuously monitoring stalk height and adjusting the pitch angle parameter accordingly, the system maintains harvesting accuracy across different stalk heights without requiring manual intervention
2Productivity
If the pitch angle is not correctly set, then harvesting speed is maintained, but non-grain material enters the harvester reducing productivity
Solution Approach 1:
The system employs feedback control by using sensors to detect stalk height and the presence of non-grain material, then automatically adjusting the pitch angle and feed roller speed to prevent contamination while maintaining harvesting efficiency
Solution Approach 2:
The harvesting system performs self-adjustment of pitch angle and feed roller speed based on sensor feedback about stalk height and material flow conditions, eliminating the need for constant manual intervention and maintaining optimal operation autonomously
3Loss of time
If manual adjustment of pitch angle is used, then device complexity is reduced, but time is lost during height transitions
Solution Approach 1:
The patent replaces manual mechanical adjustment with an automated control system that uses sensors to measure stalk height and electronically controls actuators to adjust the pitch angle, eliminating the need for manual intervention and reducing adjustment time
Solution Approach 2:
The system performs preliminary measurement of stalk height using sensors before harvesting begins, allowing the control system to pre-adjust the pitch angle and feed roller speed to optimal values, eliminating delays during height transitions
Data Source
AI summary
A control system for a row unit of a corn header includes a memory configured to store instructions and one or more processors configured to execute the instructions. The instructions, when executed by the one or more processors, cause the one or more processors to receive a signal from a sensor indicative of a measured stalk height. The instructions, when executed by the one or more processors, also cause the one or more processors determine the measured stalk height based on the signal. The instructions, when executed by the one or more processors, also cause the one or more processors to control a header pitch actuator to adjust a pitch angle of the row unit about a lateral axis of the corn header, control a speed actuator to adjust a speed of one or more feed rollers of the row unit, or a combination thereof, based on the measured stalk height.